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Vitara 1999-2005 Service Manual Canvas Top Supplemental

1. NOTE e To check whether the vehicle is equipped with a seat belt pretensioner or not refer to the Owner s Manu al e For the descriptions items not found in this section refer to the same section of the Service Manual mentioned in FOREWORD of this manual CONTENTS 10A 2 SEAT BELT ON VEHICLE SERVICE SERVICE PRECAUTIONS HANDLING AND STORAGE NOTE Whether the pretensioner has activated or not can be judged by the sealing tape attached on retractor assembly If it has been torn by generated gas the pretensioner has activated LIVE INACTIVATED SEAT BELT PRETENSIONER WARNING Never attempt to measure the resistance of the pretension er Itis very dangerous as the electric current from the tester may activate the pretensioner opecial care is necessary when handling and storing a live inacti vated pretensioner Also when the seat belt pretensioners activate gas is generated and the seat belt is retracted into the retractor quickly Note there fore that if they activate accidentally the seat belt pretensioners and other object s around them may be thrown through the air e Never attempt disassembly of the seat belt pretensioner retrac tor assembly e f any abnormality is found be sure to replace it with new one as an assembly e When an abnormality is noted as existing in the live inactivated seat belt pretensioner be sure to activate it before discarding it Refer to Seat B
2. 203 2 213 2 mm 8 00 8 40 in 125 5 135 5 mm 4 94 5 33 in Before fixing boot band insert screwdriver into boot on joint side and allow air to enter boot so that air pressure in boot be comes the same as atmospheric pressure 11 Clamp boot band Check boots for distortion or dent A Fill grease 85 g 3 0 oz FRONT DRIVE SHAFT SHAFT BEARING OIL SEAL 4 2 7 INSTALLATION Install drive shaft assembly by reversing removal procedure and noting following points e Clean front drive shaft oil seal and then apply lithium grease to oil seal and DOJ shaft j gt A Grease 99000 25010 e Check oil seal for breakage or deterioration Replace it as necessary e Drive in oil seal until its end contacts stopped surface of drive shaft joint by using a pipe whose inner diameter is 76 mm 2 992 in or more and outer diameter is 80 mm 3 150 in or less Diameter a 76 mm 2 992 in or more Diameter b 80 mm 3 150 in or less e Drive in drive shaft thrust washer Drive shaft joint Oil seal Pipe Thrust washer e RH Side Push differential side joint by hand until it is positioned by snap ring fitted to its spline LH Side Connect drive shaft flange bolts and nuts Tightening Torque a 50 N m 5 0 kg m 36 5 Ib ft e Wheninstalling axle shaft drive flange to wheel hub apply sealant to mating surface of axle shaft drive flange A Sea
3. Seat back Seat auto lock release handle Seat hinge male Hinge male cover BODY SERVICE 9 7 SEAT REMOVAL 1 Remove four mounting bolt to remove seat cushion 2 Remove four mounting bolts to remove seat back 3 Disassemble and repair seat as necessary INSTALLATION Reverse removal procedure to install rear seat Torque to specifications as shown Tightening Torque a 35 N m 3 5 kg m 25 5 Ib ft 9 8 BODY SERVICE PAINT AND COATING METAL REPLACEMENT PARTS FINISHING SEALANT APPLICATION AREA Canvas top model H H A Apply sealant 1 Side body inner panel Front floor panel 2 Rear wheel housing panel 6 Center floor member Brush treatment 3 Rear floor panel 7 Side sill inner panel 4 Center floor panel BODY SERVICE 9 9 tn lt ANS vat Key NY a Kay 7 Y MM YT E ZEW b js 3 dd 7 c D uoo CN OT LO 9 10 BODY SERVICE O I EE d lt ELLE o z 9 L e O i F aga J e CO CS gt P eic uno E Lh 7 3574 j t f O gt VD msy D Ll E es SE FE o9 599 um oe gk vL o Q e Se 5 PX EIER oD S5E z me g L Loa 0 s oo9 oo Bosses 5 2 29965 gt 2 6 ZZZ ggzccooocoqdD
4. CAUTION Be very careful not to separate roof trim consists of 4 components when removing If disassemble it it could not be assembled to original unit Canvas top Rear topbow Side body garnish Luggage mat end garnish Assistant grip Sunshade assembly Sunshade hook Front topbow lock Canvas top snap Front seat belt Front pillar trim Rear side inner lower trim Rear side inner upper trim Room light connector Room light harness clamp Roof trim Left front seat belt 1 2 3 4 5 6 7 8 9 9 18 BODY SERVICE INSTALLATION 1 Set room light and clip to roof trim 2 Set room light harness to roof trim with marking tape 1 Roof trim 2 Room light Screw 3 Room light lens Room light harness Marking tape 3 Reverse removal sequence to install roof trim Tightening Torque a 35 N m 3 5 kg m 25 3 Ib ft 1 Seat belt SEAT BELT 10 1 SECTION 10A SEAT BELT WARNING For vehicles equipped with Supplemental Restraint Air Bag System e Service on and around the air bag system components or wiring must be performed only by an autho rized SUZUKI dealer Refer to Air Bag System Components and Wiring Location View under Gener al Description in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring Please observe all WARNINGS and Service Precau tions under On Vehicle Ser
5. NOTE Don t bend interlock cable excessively when removing and installing it or system will not operate correctly Removal 1 Disconnect negative cable from battery 2 If equipped with air bag system disable air bag system Refer to Disabling Air bag System in Section 10B 3 Remove steering column hole cover 4 Tilt steering column if steering column is adjustable If no adjustable loosen steering column bolts 5 Remove steering column cover 6 Remove interlock cable clamp screw located at ignition switch ass y 7 Remove disconnect interlock cable inner end Ignition switch side 8 With console box removed take out interlock cable by loosening lock nuts 9 Detach cable end from interlock cam while pressing claws of in terlock cam boss At this time be careful not to cause damage to its claws Installation 1 Shift select lever to N range and turn ignition key to ACC posi tion 2 Connect inner end of interlock cable to key interlock lever Igni tion switch side 3 Install outer end bracket of interlock cable to ignition switch as sembly and tighten screw to specified torque Tightening Torque a 2 2 N m 0 22 kg m 1 5 Ib ft 7B1 4 AUTOMATIC TRANSMISSION 4 A T Interlock cable Steering column Steering column holder 2 3 a 4 Interlock cam Lever plate Interlock cable Pin with 4 mm 0 15 in dia 4 Pass and connect interlock ca
6. SUZUKI SQ 416 420 M Y 1998 2005 SUPPLEMENTARY SERVICE MANUAL FOR CAVANS TOP MODEL This SUPPLEMENTARY SERVICE MANUAL is a supplement to 50416 50420 50625 SER VICE MANUAL It has been prepared exclusively for the following applicable model Applicable model 50416 50420 Canvas Top Model It describes only different service information of S0416 350420 canvas top model as compared with 50416 50420 50625 SERVICE MANUAL Therefore whenever servicing SG415 50420 canvas top model consult this supplement first And for any section item or description not found in this supplement refer to the related service manual below When replacing parts or servicing by disassembling it is recommended to use SUZUKI genuine parts tools and service materials lubricants sealants etc as specified in each description All information illustrations and specifications contained in this literature are based on the latest product information available at the time of publication approval And used as the main subject of description is the unit of standard specifications among others Therefore note that illustrations may differ from the unit being actually serviced The right is served to make changes at any time without notice RELATED MANUAL 30415 S0420 S08525 Service Manual 99500 65000 5416 50420 50625 Unit Repair Manual for Manual Diferential 30416 50420 50625 Wiring Diagram Manual 99512 65001 Transmissi
7. e Never attemptto disassemble the seat belt pretensioners retrac tor assembly e f any abnormality is found be sure to replace it with new one as an assembly e When an abnormality is noted as existing in the live inactivated seat belt pretensioner be sure to activate it before discarding it e When grease cleaning agent oil water etc got on the seat belt pretensioners retractor assembly wipe it off immediately with a dry cloth e f seat belt pretensioner was dropped from a height of 30 cm 1 ft or more it should be replaced with a new one as an assembly AIR BAG SYSTEM 10 3 WARNING e For handling and storage of a live seat belt pretensioner select a place where the ambient temperature below 65 150 F without high humidity and away from electric noise Never carry the seat belt pretensioner by the wires or con nector on the underside of the pretensioner When placing a live seat belt pretensioner on the work bench or some place like that be sure not to lay it with its exhaust hole provided side facing down It is also prohib ited to put something on its face with an exhaust hole or to put a seat belt pretensioner on top of another Otherwise personal injury may result 1 Exhaust hole
8. Drive Shaft 4A2 2 FRONT DRIVE SHAFT SHAFT BEARING OIL SEAL ON VEHICLE SERVICE DRIVE SHAFT REMOVAL LEFT SIDE 1 Hoist vehicle and remove wheel 1 Oil filler level plug 2 Front drain plug 2 Remove axle shaft drive flange 3 Remove drive shaft circlip and washer 1 Circlip 2 Washer 4 Remove drive shaft flange bolts and nuts Drive shaft flange bolts and nuts 5 Remove drive shaft assembly to differential side as shown in left figure CAUTION To prevent breakage of boots wheel side and differential side be careful not to bring them into contact with other parts when removing drive shaft assembly 6 Remove drive shaft thrust washer from drive shaft and remove drive shaft oil seal as shown in figure CAUTION Be careful not to cause damage to drive shaft joint 1 Oil seal FRONT DRIVE SHAFT SHAFT BEARING OIL SEAL 4 2 3 REMOVAL RIGHT SIDE 1 Hoist vehicle and remove wheel 2 Drain differential gear oil 1 Oil filler level plug 2 Front drain plug 3 Remove axle shaft drive flange 4 Remove drive shaft circlip and washer 5 Remove knuckle and wheel hub comp refer to steps 5 to 7 and 9 to 14 of item COIL SPRING REMOVAL in Section 3D 1 Circlip 2 Washer 6 Remove drive shaft assembly To detach snap ring fitted on the spline of differential side joint inboard joint from differential side gear pull inboard joint by us ing a tire lever CAUTION To preve
9. Remove floor jack from rear axle housing Rear bolt 3 Install wheel and tighten wheel nuts to specified torque Vehicle body Axle housing Po Tightening Torque for wheel nuts 95 N m 9 5 kg m 69 0 Ib ft 4 Lower hoist and with vehicle in non loaded condition tighten front bolts and rear bolts and nuts of lower rod to specified torque Tightening Torque a 90 N m 9 0 kg m 65 0 Ib ft 3E 4 REAR SUSPENSION REAR AXLE SHAFT INNER OIL SEAL REMOVAL 1 Remove rear axle shaft For details refer to steps 1 to 7 of REAR AXLE SHAFT REMOVAL in this section 2 Fix brake back plate by inserting screwdriver to the hole for bear Ls ing retainer mounting CP 3 Remove rear axle shaft inner oil seal 1 Inner oil seal NOTE Take care bend the brake pipe INSTALLATION 1 Using special tool drive in oil seal until it contacts oil seal protec tor in axle housing NOTE e Make sure that oil seal is free from inclination as it is installed e Refer to figure so that oil seal is installed in proper direc tion Special Tool A 09913 75510 A Grease 99000 25010 2 For procedure hereafter refer to steps 6 to 11 of REAR AXLE SHAFT INSTALLATION in this section Body center 1 Oil seal protector 2 Oil seal SPECIAL TOOL 09913 75510 Oil seal installer WHEELS AND TIRES 1 SECTION WHEELS AND TIRES NOTE e All wheel fasteners are important attaching parts
10. al Description in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring Please observe all WARNINGS and Service Precau tions under On Vehicle Service in air bag system section before performing service on or around the air bag system components or wiring Failure to follow WARNINGS could result in unintentional activation of the system or could render the system inoperative Either of these two conditions may result in severe injury e Technical service work must be started at least 90 seconds after the ignition switch is turned to the LOCK position and the negative cable is disconnected from the battery Otherwise the system may be activated by reserve energy in the Sensing and Diagnostic Module SDM NOTE For the descriptions items not found in this section refer to the same section of Service Manual men tioned in FOREWORD of this manual CONTENTS 8B 2 LIGHTING SYSTEM ON VEHICLE SERVICE HAZARD RELAY INSPECTION Connect battery and tester as shown Unless a continued click sound is heard replace relay 1 Hazard relay 2 Junction box 3 Fuse box INSTRUMENTATION DRIVER INFORMATION 8 1 SECTION 8C INSTRUMENTATION DRIVER INFORMATION WARNING For vehicles equipped with Supplemental Restraint Air Bag System e Service on and around the air bag system components or wiring must be performed only by an autho rized SUZUKI dea
11. lated area and away from open flames Use special care to prevent sparking when connecting and disconnecting test lead to and from battery 1 Install injector and fuel pressure regulator to special tool injec tor checking tool Special Tool A 09912 58421 2 Connect special tools hoses and attachment to hose and pipe of vehicle Special Tool B 09912 58431 3 Connect special tool test lead to injector Special Tool D 09930 88530 4 Install suitable vinyl tube onto injector nozzle to prevent fuel from splashing out when injecting 5 Put graduated cylinder under injector as shown 6 Remove fuel pump relay 7 operate fuel pump and apply fuel pressure to injector using wire harness as thick as the one used for fuel pump circuit con nect two terminals of relay connector as shown in figure CAUTION Check to make sure that connection is made between correct terminals Wrong connection can cause damage to PCM ECM wire harness etc Turn ignition switch ON 8 Apply battery voltage to injector for 15 seconds and measure in jected fuel volume with graduated cylinder Test each injector two or three times If not within specification replace injector Injected fuel volume 42 52 cc 15 sec 1 42 1 48 1 75 1 83 US Imp 02 15 sec for G16 engine 55 62 cc 15 sec 1 94 2 09 2 18 2 36 US Imp 02 15 sec for J20 engine 6E1 10 ENGINE AND EMISSION CONTROL SYSTEM G16 J20
12. refer to the same section of the Service Manual men tioned in FOREWORD of this manual CONTENTS 3D 2 FRONT SUSPENSION ON VEHICLE SERVICE COIL SPRING REMOVAL 1 Hoist vehicle allowing front suspension to hang free 2 Remove wheels 3 Remove axle shaft drive flange 4 Remove front drive shaft circlip and washer 1 Circlip 2 Washer 5 Remove caliper bolts and suspend caliper with a wire hook CAUTION Hang removed caliper with a wire hook so as to prevent brake hose from bending and twisting excessively or be ing pulled Don t operate brake pedal with pads removed 6 If equipped with ABS remove harness clamp bolt and remove front wheel speed sensor from knuckle CAUTION e Do not pull wire harness when removing front wheel speed sensor e Do not cause damage to surface of front wheel speed sensor and do not allow dust etc to enter its installa tion hole 1 Front wheel Speed sensor 2 Harness clamp bolt Remove brake disc NOTE If brake disc can not be removed by hand use 8 mm bolts as shown 1 Coil spring FRONT SUSPENSION 3D 3 8 Remove stabilizer bar refer to steps 2 to 5 of item STABILIZ ER BAR BUSHINGS REMOVAL in this section 9 Disconnect tie rod end from knuckle by using puller 10 Support lower arm using jack as shown 11 Remove strut bracket bolts 12 Remove ball stud nut 13 Using puller disconnect knuckle from ball stud 14 Remove
13. 1 5 B 1 FUEL PUMP CIRCUIT CHECK Main fuse box IG fuse Fl fuse Ignition switch IG circuit fuse Main relay Fuel pump relay Fuel pump ECM PCM W G H A13 A23 STEP ACTION 1 Is fuel pump heard to operate 3 Fuel pump and its circuit are in Go to Step 2 seconds after ignition switch ON good condition 1 With ignition switch OFF remove Goto Step 3 P B or wire open fuel pump relay from connector poor fuel pump relay to 2 Using service wire connect coupler connection or two terminals of relay connector as faulty fuel pump shown in figure Is fuel pump heard to operate with ignition switch ON 1 Check fuel pump relay referring Poor fuel pump relay to coupler Faulty fuel pump to p 6E1 12 in this manual connection W G wire open or relay Is itin good condition poor A13 A23 connection If wire and connection are OK substitute a known good ECM PCM and recheck Right hand steering vehicle Service wire 6E1 6 ENGINE AND EMISSION CONTROL SYSTEM G16 J20 ENGINE INSPECTION OF PCM ECM AND ITS CIRCUITS PCM ECM and its circuits can be checked at PCM ECM wiring couplers by measuring voltage and resistance CAUTION PCM ECM cannot be checked by itself It is strictly prohib ited to connect voltmeter or ohmmeter to PCM ECM with couplers disconnected from it M T Vehicle 22 sse ss se ses i oor os os
14. air check that LSPV is installed properly referring to following INSPECTION amp ADJUSTMENT INSPECTION amp ADJUSTMENT Confirm the following before inspection and adjustment e Fuel tank is filled with fuel fully e Vehicle is equipped with spare tire tools jack and jack handle e Vehicle is free from any other load With vehicle in above conditions 1 Place it on level floor 2 Push up LSPV lever with finger till it stops and measure length of coil spring L in below figure as it is pulled 3 Spring length L should be the value specified below Spring length between spring ends L 103 mm 4 06 in 4 If itisn t adjust it to specification by changing stay positions as shown in left figure After adjustment tighten bolt to specified torque For details refer to left figure qM 2 Tightening Torque Se o N WO a 23 N m 2 3 kg m 17 0 Ib ft oz d NOTE 1 LSPV stay bolt Check to make sure that LSPV body and brake pipe joints 2 LSPV stay are free from fluid leakage Replace defective parts if any 5A 4 BRAKES PIPE HOSE MASTER CYLINDER TIGHTENING TORQUE SPECIFICATIONS Tightening torque LSPV mounting bolt 23 2 3 17 0 L SPV stay bolt ENGINE GENERAL INFORMATION G16 J20 H25 ENGINE 6 1 SECTION 6 ENGINE G16 J20 H25 ENGINE WARNING For vehicles equipped with Supplemental Restraint Air Bag System e Service on and around the air bag system components or wiring must
15. be performed only by an autho rized SUZUKI dealer Refer to Air Bag System Components and Wiring Location View under Gener al Description in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring Please observe all WARNINGS and Service Precau tions under On Vehicle Service in air bag system section before performing service on or around the air bag system components or wiring Failure to follow WARNINGS could result in unintentional activation of the system or could render the system inoperative Either of these two conditions may result in severe injury e Technical service work must be started at least 90 seconds after the ignition switch is turned to the LOCK position and the negative cable is disconnected from the battery Otherwise the system may be activated by reserve energy in the Sensing and Diagnostic Module SDM NOTE For the description items not found in this section refer to the same section of the Service Manual men tioned in FOREWORD of this manual CONTENTS GENERAL INFORMATION General Information on Engine Service Fuel pressure relief procedure 6 2 ENGINE GENERAL INFORMATION G16 J20 H25 ENGINE Left hand steering vehicle 1 Fuel pump relay 2 Junction Fuse box Right hand steering vehicle 1 Fuel pump relay 2 Junction Fuse box GENERAL INFORMATION GENERAL INFORMATION ON ENGINE SERVICE FUEL PR
16. be performed only by an autho rized SUZUKI dealer Refer to Air Bag System Components and Wiring Location View under Gener al Description in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring Please observe all WARNINGS and Service Precau tions under On Vehicle Service in air bag system section before performing service on or around the air bag system components or wiring Failure to follow WARNINGS could result in unintentional activation of the system or could render the system inoperative Either of these two conditions may result in severe injury e Technical service work must be started at least 90 seconds after the ignition switch is turned to the LOCK position and the negative cable is disconnected from the battery Otherwise the system may be activated by reserve energy in the Sensing and Diagnostic Module SDM NOTE For the descriptions items not found in this section refer to the same section of Service Manual men tioned in FOREWORD of this manual CONTENTS 8D 2 WINDOWS MIRRORS SECURITY AND LOCKS ON VEHICLE SERVICE WINDSHIELD WIPER INSPECTION Wiper Motor 1 As illustrated use a 12 V battery to connect its terminal to ter minal A and its terminal to Black lead wire If motor rotates at a low revolution speed of 45 to 55 rpm it is proper For high speed check connect battery terminal to ter m
17. heater control system if equipped G16 ENGINE Idle air control system e Fuel pump control system e Evaporative emission control system e Ignition control system e EGH system if equipped Also with 4 A T model PCM controls A T B i d 5 INFORMATION SENSORS CONTROLLED DEVICES OTHERS 1 MAF sensor a Fuel pump relay A PCM ECM 2 VSS b Injectors B EVAP canister 3 Heated oxygen sensor if equipped c EGR valve if equipped C Data link connector 4 Power steering pressure switch d Idle air control valve D Combination meter if equipped e Ignition coil assemblies 5 ECT sensor g Malfunction indicator lamp 6 Battery CHECK ENGINE light 7 TP sensor h Main relay 8 Transmission range switch A T only i EVAP canister purge valve 9 Camshaft position sensor CMP sensor 10 IAT sensor 11 Ignition timing adjusting resistor 12 CO adjusting resistor if equipped 13 ABS control module if equipped 14 A C amplifier if equipped 15 Monitor connector A C condenser fan motor relay if equipped Above figure shows left hand steering vehicle For right hand steering vehicle parts with are installed at the other side ENGINE AND EMISSION CONTROL SYSTEM G16 J20 ENGINE 6E1 3 J20 ENGINE 9 8 9 NCC IA ERE ee i L INFORMATION SENSORS CONTROLLED DEVICES OTHERS 1 IAT sensor a Idle air control valve A ECM PCM 2 MAF sensor b A C condenser fa
18. previously described procedure G16 LH steering vehicle Manifold gauge set High pressure side Delivery side hose Low pressure side Suction side pipe AIR CONDITIONING OPTIONAL 1B 13 COMPRESSION SYSTEM COMPRESSOR INSPECTION 1 Install manifold gauge set as illustrated 2 Close Hi and Lo hand valves 3 Run engine at fast idle 4 Check compressor for following a High pressure gauge reading is not low and low pressure gauge reading is not higher than normal b Metallic sound c Leakage from shaft seal If any ofthe above checks indicated a defect repair compressor REMOVAL 1 Run engine at idle with A C ON for 10 minutes 2 Disconnect negative cable at battery 3 Recover refrigerant from refrigeration system using recovery and recycling equipment NOTE The amount of compressor at removed must be measured and the same amount must be poured when installing the compressor 4 Disconnect thermal protector lead wire 5 Disconnect suction and discharge hoses from compressor NOTE Cap open fitting immediately to keep moisture out of sys tem 6 For G16 engine Remove compressor drive belt by loosening compressor mounting bolts For J20 engine Hemove generator belt Refer to Section 6H for details 7 Remove compressor with clutch assy from its mount 8 Drain oil from compressor and measure its amount 1B 14 AIR CONDITIONING OPTIONAL INSTALLATION 1 Pour new compressor oil T
19. rized SUZUKI dealer Refer to Air Bag System Components and Wiring Location View under Gener al Description in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring Please observe all WARNINGS and Service Precau tions under On Vehicle Service in air bag system section before performing service on or around the air bag system components or wiring Failure to follow WARNINGS could result in unintentional activation of the system or could render the system inoperative Either of these two conditions may result in severe injury e Technical service work must be started at least 90 seconds after the ignition switch is turned to the LOCK position and the negative cable is disconnected from the battery Otherwise the system may be activated by reserve energy in the Sensing and Diagnostic Module SDM NOTE For the descriptions items not found in this section refer to the same section of the Service Manual men tioned in FOREWORD of this manual CONTENTS ON VEHICLE SERVICE Manual Selector Assembly For LH Vehicle Key Interlock Cable If Equipped 7B1 2 AUTOMATIC TRANSMISSION 4 A T ON VEHICLE SERVICE MANUAL SELECTOR ASSEMBLY FOR LH VEHICLE Manual selector assembly Select lever assembly Manual lever assembly Select cable bracket Select indicator Slide cover Select lever knob Spring Knob button Shift lo
20. the filter from the receiver 1B 8 AIR CONDITIONING OPTIONAL 4 Remove the dryer using a plier INSTALLATION Reverse removal sequence to install condenser dryer according to instruction manual with supply parts NOTE e When replacing condenser dryer add 40 cc of refrigerating oil the same as compressor oil e Do notremove the dryer from the plastic bag until just before inserting it into the receiver e Install the condenser dryer with its double layer portion fac ing the bottom of the receiver Cap Tightening Torque 12 5 2 5 Nm 1 25 0 25 kg m 9 1 8 lb ft FILTER ELEMENT REMOVAL 1 Disconnect negative cable at battery 2 For vehicle with air bag system disable air bag system Refer to DISABLING AIR BAG SYSTEM in Section 10B LH steering vehicle shown LH steering vehicle shown 3 Pull down glove box AIR CONDITIONING OPTIONAL 1B 9 LH steering vehicle shown 4 Remove filter cover 1 Filter cover LH steering vehicle shown 5 Pull out filter element Pull out upper filter first then the lower one ee LI A wi Af TAN 1 Filter element CLEAN Blow off dust by compressed air from air outlet side of the filter ele ment FM uv 1 Air flow INSTALLATION Reverse removal procedure for installation noting the followings e Install filter into cooling unit directing arrow mark on its end face to heater unit e Ena
21. wire harness is caught between them 5 Make sure that clearance between module and steering wheel is uniform all the way 6 Tighten driver air bag inflator module mounting bolt left side to specified torque first and then driver air bag inflator module mounting bolt right side to specified torque Tightening Torque a 9 N m 0 9 kg m 6 5 Ib ft 7 Install mounting bolt hole caps 2 pcs 8 Connect negative battery cable 9 Enable air bag system Refer to Enabling Air Bag System un der Service Precautions in SECTION 10B Driver air bag inflator module connector Horn connector Driver air bag inflator module Steering wheel Mounting bolt left side Mounting bolt right side FRONT SUSPENSION 3D 1 SECTION 3D FRONT SUSPENSION CAUTION e All front suspension fasteners are an important attaching part in that it could affect the performance of vital parts and systems and or could result in major repair expense They must be replaced with E one of the same part number or with an equivalent part if replacement becomes necessary Do not use a replacement part of lesser quality or substitute design Torque values must be used as specified during reassembly to assure proper retention of this part Never attempt to heat quench or straighten any front suspension part Replace it with a new part or damage to the part may result NOTE For the descriptions items not found in this section
22. 3E Bete EEEREEEEFI A T Vehicle oT Se 6 gt Rl uff 1 PCM ECM 2 PCM ECM connector Viewed from harness side Voltage Check Hefer to the same item of the Service Manual mentioned in Fore word of this manual ENGINE AND EMISSION CONTROL SYSTEM G16 J20 ENGINE 6 1 7 Resistance Check 1 Disconnect couplers from ECM POM with ignition switch OFF CAUTION Never touch terminals ECM PCM itself or connect voltmeter or ohmmeter 2 Check resistance between each pair of terminals of discon nected couplers as listed in following table CAUTION e Be sure to connect ohmmeter probe from wire harness side of coupler e Be sure to turn OFF ignition switch for this check e Resistance in table represents that when parts temper ature is 20 C 68 F 1 ECM PCM coupler disconnected 2 Ohmmeter M T VEHICLE TERMINALS CIRCUIT CONDITION A13 B15 Fuel pump relay 79 95 Q SS Battery disconnected and A26 B15 A C fan motor relay if equipped 75 110 9 ignition switch ON D1 B8 Fuel injector No 2 13 160 D2 B8 Fuel injector No 1 D4 B8 IAC valve stepper motor coil 1 07 B8 EGR valve stepper motor coil 2 if equipped 20 24 Q EGR valve stepper motor coil 1 D8 B8 if equipped D9 B15 Heater of HO2S if equipped 11 7 14 3 D12 B8 Fuel injector No 4 a 13 160 D13 B8 Fuel injector No 3 D3 B8 IAC v
23. ENGINE 9 Check fuel leakage from injector nozzle Do not operate injector Injector Vinyl tube for this check but fuel pump should be at work Less than one fuel drop min Graduated cylinder If fuel leaks more than the following specifications replace Fuel leakage Less than 1 drop min ENGINE AND EMISSION CONTROL SYSTEM G16 J20 ENGINE 6 1 11 Left hand steering vehicle ELECTRONIC CONTROL SYSTEM MAIN RELAY Inspection 1 Disconnect negative cable at battery 2 Remove main relay from connector 1 Main relay 2 Junction Fuse box Right hand steering vehicle 3 Check resistance between each two terminals as in table below TERMINALS RESISTANCE Between A and B oo Infinity Between C and D 79 95 Q at 20 C 68 F If check results are as specified proceed to next operation check If not replace 4 Check that there is continuity between terminals A and B when battery is connected to terminals C and D If malfunction is found replace 6E1 12 ENGINE AND EMISSION CONTROL SYSTEM G16 J20 ENGINE Left hand steering vehicle SS SE F 1 Fuel pump relay 2 Junction Fuse box Right hand steering vehicle 1 A FUEL PUMP RELAY Inspection 1 Disconnect negative cable at battery 2 Remove fuel pump relay from connector 3 Structure of fuel pump relay is the same as that of main relay Check its resistance and operation using the same procedur
24. ESSURE RELIEF PROCEDURE CAUTION This work must not be done when engine is hot If done so it may cause adverse effect to catalyst After making sure that engine is cold relief fuel pressure as follows 1 Place transmission gear shift lever in Neutral shift selector le ver to P range for A T vehicle set parking brake and block drive wheels 2 Remove fuel pump relay from connector 3 Remove fuelfiller cap to release fuel vapor pressure in fuel tank and then reinstall it 4 Start engine and run ittill it stops for lack of fuel Repeat cranking engine 2 3 times of about 3 seconds each time to dissipate fuel pressure in lines Fuel connections are now safe for servicing 5 Upon completion of servicing install fuel pump relay to connec tor ENGINE AND EMISSION CONTROL SYSTEM G16 J20 ENGINE 6 1 1 SECTION 6E1 ENGINE AND EMISSION CONTROL SYSTEM SEQUENTIAL MULTIPORT FUEL INJECTION FOR G16 J20 ENGINE WARNING For vehicles equipped with Supplemental Restraint Air Bag System e Service on and around the air bag system components or wiring must be performed only by an autho rized SUZUKI dealer Refer to Air Bag System Components and Wiring Location View under Gener al Description in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring Please observe all WARNINGS and Service Precau tions under On Vehicle Service in air
25. For handling and storage of a live seat belt pretensioner select a place where the ambient temperature below 65 150 F without high humidity and away from electric noise e Never carry seat belt pretensioner by wire or connector of pretensioner When placing a live seat belt pretensioner on the workbench or some place like that be sure not to lay it with its exhaust hole provided side facing down It is also prohibited to put something on its face with an ex haust hole or to put a seat belt pretensioner on top of another Otherwise personal injury may result Never dispose of live inactivated seat belt pretensioners driver and passenger If disposal is necessary be sure to activate them according to activation procedures de scribed in SECTION 10B before disposal The seat belt pretensioner immediately after activation is very hot Wait for at least half an hour to cool it off before proceeding the work e With many service procedures gloves and safety glasses should be worn to prevent any possible irritation of the skin or eyes GENERAL INFORMATION 0 5 CAUTION e Even when the accident was light enough not to cause air bags to activate be sure to inspect system parts and other related parts according to instructions under Repair and Inspection Required after an Accident in SECTION 10B e When servicing parts other than air bag system if shocks may be applied to air bag system component parts re move tho
26. TER CYLINDER ON VEHICLE SERVICE LSPV Load Sensing Proportioning Valve ASSEMBLY if equipped REMOVAL 1 Clean around reservoir cap and take out fluid with syringe or such 2 Hoist vehicle 3 Disconnect brake pipes from LSPV 2 Brake pipe 4 Remove LSPV assembly from vehicle body NOTE As shown in figure left LSPV assembly should be removed together with its spring and stay installed or rear axle hous ing 5 Remove spring and stay from lever CAUTION e LSPV assembly must not be disassembled Replace with new one if defective e Stopper bolt should not be loosened or tightened LSPV assembly LSPV spring LSPV stay Bolt INSTALLATION CAUTION Refer to above CAUTION Install by reversing removal procedure noting the following 1 Apply multi purpose grease to upper and lower joint of coil spring A Apply grease BRAKES PIPE HOSE MASTER CYLINDER 5A 3 2 Torque each bolt and nut to specification as indicated respec tively in figure left Tightening Torque a 23 N m 2 3 kg m 17 0 Ib ft b 16 N m 1 6 kg m 11 5 Ib ft brake flare nut c 7 5 0 75 kg m 9 0 Ib ft bleeder plug 3 Upon completion of installation fill reservoir tank with specified LSPV stay bolt fluid and bleed air from brake system LSPV bolt Brake pipe flare nut NOTE Air bleeding plug Make sure to bleed air from LSPV bleeder without failure 4 After bleeding
27. TION e Do not pull wire harness or twist more than necessary when installing front wheel speed sensor e Fit harness grommet to inner fender securely e Check that there is no clearance between sensor and knuckle 3D 6 FRONT SUSPENSION KNUCKLE WHEEL SPINDLE REMOVAL 1 Hoist vehicle and remove wheel 2 Remove axle shaft drive flange drive shaft circlip and washer Refer to steps 3 to 4 of item COIL SPRING REMOVAL in this section 3 Remove wheel hub Refer to steps 3 to 9 of item WHEEL HUB BEARING OIL SEAL REMOVAL in this section 4 Disconnect tie rod end from knuckle 5 Remove ball stud nut 6 Support lower arm with jack 7 Remove strut bracket bolts from strut bracket 1 Strut 2 Knuckle 8 By using puller disconnect knuckle from ball stud 9 While lowering jack remove knuckle wheel spindle comp 10 Remove inner oil seal dust cover and wheel spindle 1 Dust cover 2 Wheel spindle 3 Knuckle 4 Inner oil seal 1 Wheel spindle 2 Drive shaft bearing Wheel spindle 2 Drive shaft bearing Front drive shaft thrust washer Inner oil seal 1 Drive shaft bearing 2 Wheel spindle FRONT SUSPENSION 3D 7 11 Remove drive shaft bearing by using special tool Special Tool 09923 74510 B 09930 30102 INSTALLATION Reverse removal sequence to install knuckle wheel spindle oil seal and drive shaft bearing noting following points e Install front drive shaft thrust wash
28. alve stepper motor coil 2 35 43 Q D14 B8 IAC valve stepper motor coil 4 m D15 B8 IAC valve stepper motor coil 3 D18 B8 EGR valve stepper motor coil 4 if equipped D19 B8 EGR valve stepper motor coil 3 if equipped 2 Body ground Ground Continuity A14 Body ground Ground Continuity A15 Body ground Ground Continuity 6E1 8 ENGINE AND EMISSION CONTROL SYSTEM G16 J20 ENGINE A T VEHICLE TERMINALS CIRCUIT CONDITION anon n D8 B4 Fuel injector No 4 D9 B4 Fuel injector No 3 B4 D10 B4 IAC valve stepper motor coil 4 D11 B4 IAC valve stepper motor coil 3 D12 B4 IAC valve stepper motor coil 2 D13 B4 EGR valve stepper motor coil 4 if equipped D14 B4 EGR valve stepper motor coil 3 if equipped D1i5 B4 EGR valve stepper motor coil 2 if equipped D16 B4 EGR valve stepper motor coil 1 if equipped D17 B4 EVAP canister purge valve Fuel feed pipe and hose Fuel injector Fuel pressure regulator Fuel return pipe Left hand Right hand steering vehicle steering vehicle Fuel pump relay connector Service wire Junction Fuse box 1 Injector 3 Keep as far apart 2 Battery as possible ENGINE AND EMISSION CONTROL SYSTEM G16 J20 ENGINE 6 1 9 ON VEHICLE SERVICE FUEL DELIVERY SYSTEM FUEL INJECTOR Inspection WARNING As fuel is injected in this inspection perform in a well venti
29. and recycling equipment EE Be sure to follow the instruction manual for the equipment The amount of compressor oil removed must be measured and the same amount added to the system Lawersiay y 3 Remove front bumper assembly and lower stay Refer to Sec E tion 9 BODY SERVICE 4 Disconnect compressor delivery hose from condenser inlet fit tings NOTE As soon as above hose and pipe are disconnected cap opened fittings so that moisture and dust do not enter con denser 1 Compressor delivery hose 1 Dual pressure switch 2 Condenser cooling fan motor coupler 3 Condenser outlet pipe 1 Condenser assembly 2 Condenser dryer section 1 Filter AIR CONDITIONING OPTIONAL 1B 7 5 Disconnect coupler from dual pressure switch 6 Disconnect condenser outlet pipe 7 Disconnect condenser cooling fan motor coupler 8 Remove condenser with fan NOTE Be careful not to damage fins of condenser and radiator 9 Remove cooling fan from condenser INSTALLATION Reverse removal sequence to install condenser noting following point 1 When replacing condenser add 20 to 30 cc of refrigerating oil from compressor suction side 2 Evacuate and charge system according to previously described procedure REPLACEMENT OF CONDENSER DRYER REMOVAL 1 Remove condenser assembly from vehicle refer to CON DENSER ASSEMBLY REMOVAL in this section 2 Remove the cap using a hexagon wrench 3 Remove
30. bag system section before performing service on or around the air bag system components or wiring Failure to follow WARNINGS could result in unintentional activation of the system or could render the system inoperative Either of these two conditions may result in severe injury e Technical service work must be started at least 90 seconds after the ignition switch is turned to the LOCK position and the negative cable is disconnected from the battery Otherwise the system may be activated by reserve energy in the Sensing and Diagnostic Module SDM H NOTE e For the descriptions items not found in this section refer to the same section of the Service Manual mentioned in FOREWORD of this manual e Whether the following systems parts are used in the particular vehicle or not depends on specifica tions Be sure to bear this in mind when performing service work EGR valve Heated oxygen sensor or CO adjusting resistor Three way catalytic converter CONTENTS 6E1 2 ENGINE AND EMISSION CONTROL SYSTEM G16 J20 ENGINE GENERAL DESCRIPTION ELECTRONIC CONTROL SYSTEM The electronic control system consists of 1 various sensors which detect the state of engine and driving conditions 2 ECM PCM which controls various de vices according to the signals from the sensors and 3 various controlled devices Functionally it is divided into the following sub sys tems e Fuel injection control system e Heated oxygen sensor
31. ble air bag system after installation Refer to ENABLING AIR BAG SYSTEM in Section 10B MOM uv EVAPORATOR COOLING UNIT REMOVAL 1 Disconnect negative cable at battery 2 Disable air bag system Refer to Disabling Air Bag System in Section 10B 3 Recover refrigerant by using recovery and recycling equipment Be sure to follow the instruction manual for the equipment The amount of compressor oil removed must be measured and the same amount added to the system 1B 10 AIR CONDITIONING OPTIONAL 1 Suction pipe 2 Liquid pipe LH steering vehicle 1 Cover 2 Filter 3 Evaporator assembly 1 Screw Upper case Evaporator Lower case Thermistor Expansion valve 4 Disconnect suction pipe and liquid pipe from evaporator cool ing unit NOTE As soon as above hose and pipe are disconnected cap opened fittings so that moisture and dust may not enter cooling unit 5 Remove blower motor unit Refer to Section 1A HEATER AND VENTILATION 6 Disconnect thermistor wire coupler 7 Remove evaporator with evaporator case DISASSEMBLY 1 Remove filter assembly if equipped 2 Remove screws to separate evaporator upper and lower cases from each other 3 Remove upper case and remove evaporator from lower case 4 Remove following components from evaporator e Expansion valve e Thermistor 1 Suction hose 2 Condenser outlet pipe 3 Pipe clamp 1 Suction pipe 2 L
32. ble as shown at the left figure 5 Fixinterlock cam by inserting pin with about 4 mm 0 15 in dia into holes of cam and lever plate 6 Install cable end to interlock cam and stud bolt and after making sure that cable outer is pushed in arrow direction B by leaf spring tighten mounting nut to specified torque Remove pin Tightening Torque a 13 1 3 kg m 9 5 Ib ft Turn ignition key to ACC position and shift select lever to N range and check for followings a When select lever is shifted at P range with knob button depressed ignition key can not be turned from ACC to LOCK position b When knob button is released ignition key can be turned to LOCK position c When ignition key is at LOCK position select lever can not be shifted from P to any other range Install console box Install steering column cover and steering column hole cover Adjust steering column or tighten steering column bolts If equipped with air bag system enable air bag system Refer to Enabling Air bag System in Section 10B 8 9 0 1 7 Sr Nr SN i LIGHTING SYSTEM 8B 1 SECTION 8B LIGHTING SYSTEM WARNING For vehicles equipped with Supplemental Restraint Air Bag System e Service on and around the air bag system components or wiring must be performed only by an autho rized SUZUKI dealer Refer to Air Bag System Components and Wiring Location View under Gener
33. ck solenoid rod Shift lock solenoid Cover Illumination lamp Interlock cam Tightening Torque Manual selector assembly bolts 18 N m 1 8 kg m 13 5 Ib ft REMOVAL 1 Disconnect negative cable at battery 2 Remove console box 3 Disconnect connector for illumination lamp shift lock solenoid if equipped and overdrive OFF switch 4 Disconnect interlock cable from interlock cam of selector as sembly if equipped 5 Remove selector assembly mounting bolts 6 Disconnect select cable from lever of selector assembly INSTALLATION NOTE If equipped with brake interlock system new selector assem bly is supplied with held interlock cam at interlock cable con necting position with pin Remove this pin after connecting in terlock cable to interlock cam and tightening cable nut 1 Interlock cam pin only for new selector assembly Reverse removal procedure to install noting the followings e Connect interlock cable end to cam referring to Interlock Cable Installation section if equipped e Upon completion of installation confirm that brake key interlock system operates properly if equipped Ignition switch side 1 Ignition switch ass y 2 Clamp screw 3 Interlock cable 1 Inner end of interlock cable 4 Cam boss 2 Interlock cam 3 Stud bolt 1 Ignition switch ass y 2 Clamp screw 3 Outer end AUTOMATIC TRANSMISSION 4 A T 7B1 3 KEY INTERLOCK CABLE IF EQUIPPED
34. curely Special Tool A 09943 55010 7 Install tie rod end lock nut and tie rod end to tie rod Position lock nut to marking made in removal NOTE When tie rod was replaced measure length A on re moved tie rod and use it on new replacement tie rod so as to position lock nut properly 8 Install steering gear case Refer to POWER STEERING GEAR BOX ASSEMBLY INSTALLATION in this section POWER STEERING P S SYSTEM 3B1 5 POWER STEERING PUMP A Tightening Torque a 60 N m 6 0 kg m 43 5 Ib ft b 25 N m 2 5 kg m 18 5 Ib ft 55 N m 5 5 kg m 40 0 Ib ft e 35 3 5 kg m 25 5 Ib ft f 40 N m 4 0 kg m 29 0 Ib ft B 4 x 6 A G16 Type engine B J20 Type engine 1 Power steering pump assembly 4 High pressure hose amp pipe 6 Low pressure return hose 2 Bracket 5 Suction hose 7 Oil tank bracket 3 Power steering oil tank 3B1 6 POWER STEERING P S SYSTEM TIGHTENING TORQUE SPECIFICATIONS Tightening torque b G16 Type engine Pump bracket bolt J20 Type engine Tie rod LH steering vehicle SPECIAL TOOL 09943 55010 Boot clamp plier AIR BAG STEERING WHEEL AND COLUMN 3 1 1 SECTION 3C1 AIR BAG STEERING WHEEL AND COLUMN WARNING e Service on and around the air bag system components or wiring must be performed only by an autho rized SUZUKI dealer Please observe all WARNINGS and Service Precautions under On Vehicle Se
35. d tools or tire irons alone to change tires as they may damage tire beads or wheel rim Rim bead seats should be cleaned with wire brush or coarse steel wool to remove lubricants old rubber and light rust Before mount ing or demounting tire bead area should be well lubricated with ap proved tire lubricant After mounting inflate to 240 kPa 35 psi so that beads are com pletely seated Then adjust pressure to specified shown on tire placard WARNING Do not stand over tire when inflating Bead may break when bead snaps over rim s safety hump and cause serious per sonal injury Do not exceed 240 kPa 35 psi pressure when inflating If 240 kPa 35 psi pressure will not seat beads deflate re lu bricate and reinflate Over inflation may cause bead to break and cause serious personal injury Install valve core and inflate to proper pressure TIRE REPAIR There are many different materials and techniques on the market to repair tires As not all of these work on all types of tires tire manufacturers have published detailed instructions on how and when to repair tires These instructions can be obtained from the tire manufacturer FRONT DRIVE SHAFT SHAFT BEARING OIL SEAL 4A2 1 SECTION 4A2 FRONT DRIVE SHAFT SHAFT BEARING OIL SEAL NOTE For the descriptions items not found in this section refer to the same section of the Service Manual men tioned in FOREWORD of this manual CONTENTS ON VEHICLE SERVICE
36. e as that for main relay If malfunction is found replace CHARGING SYSTEM 6 1 SECTION 6H CHARGING SYSTEM WARNING For vehicles equipped with Supplemental Restraint Air Bag System e Service on and around the air bag system components or wiring must be performed only by an autho rized SUZUKI dealer Refer to Air Bag System Components and Wiring Location View under Gener al Description in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring Please observe all WARNINGS and Service Precau tions under On Vehicle Service in air bag system section before performing service on or around the air bag system components or wiring Failure to follow WARNINGS could result in unintentional activation of the system or could render the system inoperative Either of these two conditions may result in severe injury e Technical service work must be started at least 90 seconds after the ignition switch is turned to the LOCK position and the negative cable is disconnected from the battery Otherwise the system may be activated by reserve energy in the Sensing and Diagnostic Module SDM NOTE e For the descriptions items not found in this section refer to the same section of the Service Manual mentioned in FOREWORD of this manual e As regards items for 70A type generator which are not found in this section of this manual refer to each item applicab
37. ection and if it is lower to direction b e Repeat steps 3 and 4 until rear brake pressure is within spec 1 LSPV lever ification 2 LSPV spring 3 LSPV stay e After adjustment be sure to torque nut to specification 5 Disconnect brake pipe connecting between master cylinder secondary side and 4 way joint from master cylinder Tighten plug special tool to master cylinder Depress brake pedal If rear brake pressure is 95 100 kg cm when front brake pressure is 100 kg cm2 it means that front fail safe system functions properly 10000 kPa 9500 10000 kPa 100 kg cm 95 100 kg cm 1422 psi 1350 1422 psi Special Tool A 09956 02210 1 Master cylinder 2 Disconnect brake pipe for LH steering vehicle 3 Disconnect brake pipe for RH steering vehicle 6 Upon completion of fluid pressure test bleed brake system and perform brake test TIGHTENING TORQUE SPECIFICATIONS Tightening torque Fastening parts LSPV mounting bolt 23 2 0 17 0 LSPV stay bolt BRAKES PIPE HOSE MASTER CYLINDER 5 1 SECTION 5A BRAKES PIPE HOSE MASTER CYLINDER WARNING For vehicles equipped with Supplemental Restraint Air Bag System e Service on and around the air bag system components or wiring must be performed only by an autho rized SUZUKI dealer Refer to Air Bag System Components and Wiring Location View under Gener al Description in air bag system section in order to confirm
38. elt Pretensioners Disposal in SECTION 10B e When grease cleaning agent oil water etc got on the seat belt pretensioner retractor assembly wipe it off immediately with a dry cloth e f seat belt pretensioner retractor assembly was dropped from a height of 30 cm 1 ft or more it should be replaced Exhaust hole SEAT BELT 10A 3 WARNING e For handling and storage of alive seat belt pretensioner select a place where the ambient temperature below 65 C 150 F without high humidity and away from elec tric noise e Never carry the seat belt pretensioner by the wires or connector on the underside of the pretensioner e When placing a live seat belt pretensioner on the work bench or some place like that be sure not to lay it with its exhaust hole provided side facing down It is also pro hibited to put something on its face with an exhaust hole or to put a seat belt pretensioner on top of another Otherwise personal injury may result FRONT SEAT BELT WITH PRETENSIONER INSPECTION When checking seat belt with pretensioner use following check items in addition to those specified for seat belt without pretension er described in the same section of the Service Manual mentioned in FOREWORD of this manual WARNING Never measure resistance of pretensioner or disassemble it Otherwise personal injury may result CAUTION If seat belt pretensioner retractor assembly was dropped from a height of 30 c
39. em components or wiring Failure to follow WARNINGS could result in unintentional activation of the system or could render the system inoperative Either of these two conditions may result in severe injury e Technical service work must be started at least 90 seconds after the ignition switch is turned to the LOCK position and the negative cable is disconnected from the battery Otherwise the system may be activated by reserve energy in the Sensing and Diagnostic Module SDM NOTE e For the descriptions items not found in this section refer to the same section of the Service Manual mentioned in FOREWORD of this manual e Power Steering Gear Box cannot be disassembled or adjusted e All steering gear fasteners are important attaching parts in that they could affect the performance of vital parts and systems and or could result in major repair expense They must be replaced with one of the same part number or with an equivalent part if replacement becomes necessary Do not use a replace ment part of lesser quality or substitute design Torque values must be used as specified during reas sembly to assure proper retention of these parts CONTENTS GENERAL DESCRIPTION ON VEHICLE SERVICE Rack Boot Tie rod Power Steering TIGHTENING TORQUE SPECIFICATIONS SPECIAL TOOL 3B1 2 POWER STEERING P S SYSTEM GENERAL DESCRIPTION The power steering P S system in this vehicle reduces the driver s effort needed in turning the stee
40. er with its chanfered side facing to drive shaft side e Install drive shaft bearing by using special tool Special Tool A 09913 80112 Depth a 1 75 2 50 mm 0 069 0 098 in NOTE e When installing wheel spindle to knuckle coat their mating surfaces with sealant A Sealant 99000 31110 e Also fill recess in wheel spindle with about 10 g lithium grease Grease 99000 25010 e Tighten wheel spindle nut to specified torque Tightening Torque a 50 N m 5 0 kg m 36 5 Ib ft 3D 8 FRONT SUSPENSION Press fitting inner oil seal Drive in inner oil seal until its end contacts stepped surface of knuckle using special tools Special Tool B 09944 66010 C 09924 74510 Apply lithium grease to oil seal lip and into its hollow to fill more than 60 of its vacant space Grease 99000 25010 e Press fit front drive shaft thrust washer to drive shaft if it is re moved 1 Thrust washer e Tighten control arm ball stud nut When tightening ball stud nut use new nut and tighten it to speci fied torque Tightening Torque a 60 N m 6 0 kg m 43 5 Ib ft e When installing axle shaft drive flange to wheel hub apply sealant to mating surface of axle shaft drive flange Sealant 99000 31090 Tightening Torque a 48 N m 4 8 kg m 35 0 Ib ft e For installation procedures following the above refer to WHEEL HUB BEARING OIL SEAL INSTALLATION of this sect
41. erous as the electric current from the tester may deploy the air bag or ac tivate the pretensioner GENERAL INFORMATION 0A 3 SERVICING AND HANDLING ALWAYS CARRY AIR BAG INFLATOR MODULE AIR BAG OPENING AWAY WARNING Many of service procedures require disconnection of AIR BAG fuse and all air bag inflator module s from initiator circuit to avoid an accidental deployment Driver and Passenger Air Bag Inflator Modules e For handling and storage of alive air bag inflator module select a place where the ambient temperature below 65 150 F without high humidity and away from electric noise e When carrying a live air bag inflator module make sure the bag opening is pointed away from you In case of an accidental deployment the bag will then deploy with mini mal chance of injury Never carry the air bag inflator module by the wires or connector on the underside of the module When placing a live air bag inflator module on a bench or other surface always face the bag up away from the surface As the live passenger air bag inflator module must be placed with its bag trim cover facing up place it on the workbench with a slit or use the workbench ALWAYS PLACE AIR BAG INFLATOR MODULE vise to hold it securely at its lower mounting bracket This OPENING UP AWAY FROM LOOSE ORIFCTS is necessary so that a free space is provided to allow the air bag to expand in the unlikely event of accidental de p
42. g care not to damage painted surface 1 Side body 2 Fender 3 Pad 2 Attach new pad cutting appropriately size temporarily and adjust height with a knife so that fender becomes flush with side body 3 Reverse removal procedure for installation NOTE If paint on fender bolt is peeled off be sure to apply paint again 1 Side body 2 Pad 3 Knife BODY SERVICE 9 3 REAR BUMPER 1 Rear bumper 2 Rear bumper member 3 Rear bumper garnish if equipped 9 4 BODY SERVICE BODY DIMENSIONS Canvas top model C i ANY 2 AU Hole to hole distance 981 mm 38 62 in a c b b b c e e e i f i 1390 mm 1404 mm 1008 mm 1110 mm 1036 mm 54 72 in 55 28 in 39 69 in 43 70 in 40 79 in 27 09 in a N m Am OS 688 mm O zi f Sooo ioo JI Q WH a 2 J j k g g g h h i 1459 mm N ame AM Garnish installation clip hole Front end of front windshield lower installation section Front end of front windshield upper installation section Hole in F door lower hinge at rear Trim installation clip hole Scuff installation hole at rearmost end Trim installation hole 11 jig hole Installation hole for F seat front inside Installation hole for F seat rear inside F seat belt installation hole I
43. g of lever ii After unlocked disconnect connector WARNING Special care is necessary when handling and storing a live undeployed air bag inflator module Observe Service Precautions under On Vehicle Service in SECTION 10B Otherwise personal injury may result Driver air bag inflator module connector Horn connector Driver air bag inflator module Steering wheel 3C1 4 AIR BAG STEERING WHEEL AND COLUMN INSPECTION WARNING Never disassemble air bag inflator module or measure its resistance Otherwise personal injury may result CAUTION If air bag inflator module was dropped from a height of 90 cm 3 ft or more it should be replaced Check air bag inflator module visually and if any of the following is found replace it with a new one e Air bag being deployed e Trim cover pad surface being cracked e Wire harness or connector being damaged e Air bag inflator module being damaged or having been exposed to strong impact dropped 1 Trim cover pad surface 2 Inflator case 3 Wire harness INSTALLATION 1 Connect horn connector securely 2 Connect yellow connector of driver air bag inflator module con nector as shown in the figure securely i Connect connector li Lock connector with lock lever 3 Install horn connector and driver air bag inflator module con nector 4 Install driver air bag inflator module to steering wheel taking care so that no part of
44. ge when charged with specified amount About 200 300 kPa 2 3 kg cm2 29 43 psi At A C inlet temperature 30 35 86 95 F High pressure gauge when charged with specified amount About 1370 1670 kPa 14 17 kg cm2 200 244 psi At A C inlet temperature 30 35 86 95 F 1B 6 AIR CONDITIONING OPTIONAL ON VEHICLE SERVICE REFRIGERATING SYSTEM CHECK AND SUPPLEMENT OF REFRIGERANT To check if refrigerant is properly charged or not perform COR RECTIVE MEASURES FOR MALFUNCTION SYMPTOMS in this section As a result if adjustment a proper amount of refrigerant is neces sary for refrigerant system Charge a proper amount of refrigerant to refrigerant system accord ing to charging procedure described in recovery evacuation and charging NOTE Do not perform an additional refrigerant charging to A C sys tem This cause it to overcharge CONDENSER ASSEMBLY INSPECTION Check a condenser fins for blockage b condenser fittings for leak age and c condenser fins for damage Clogged condenser fins should be washed with water and should be dried with compressed air NOTE Be careful not to damage condenser fins If condenser fin is bent straighten it by using a screwdriver or pair of pliers If any leakage is found from fitting or tube repair or replace con denser Cll REMOVAL 1 Disconnect negative cable at battery 2 Recover refrigerant by using recovery
45. he amount must be the same with the amount measured in REMOVAL G16 engine NOTE Compressor assembly supplied from factory is filled up with following amount of oil Amount of oil in compressor 120 cm 120 cc 7 5 in m For G16 engine Install compressor temporarily to bracket then install compres sor drive belt For J20 engine Install compressor to its bracket Tighten bolts a first then b Tightening Torque a b 23 N m 2 3 kg m 17 0 Ib ft 3 Connect suction and discharge hoses to compressor J20 engine 4 For G16 engine Nn Tension compressor drive belt by tightening compressor mount ing bolts Refer to Section 3B1 for drive belt tension Tighten bolt a first then b Tightening Torque a 23 N m 2 3 kg m 17 0 Ib ft For J20 engine Install generator belt Refer to Section 6H for details 5 Connect thermal protector lead wire 6 Evacuate and charge system according to previously described procedure CAUTION Be sure to use HFC 134a R 134a compressor oil 1 Generator belt 3 Compressor pulley 2 Compressor drive belt 4 Crankshaft pulley MAGNET CLUTCH 1 Armature plate AIR CONDITIONING OPTIONAL 1B 15 Armature plate bolt Armature plate Circlip Magnet clutch Shim Magnet clutch coil Compressor body assembly INSPECTION a Inspect pressure plate and rotor for signs of oil b Check clutch bearings for noise and grease leakage c Us
46. hing in degreaser causes deterioration of boot FRONT DRIVE SHAFT SHAFT BEARING OIL SEAL 4 2 5 ASSEMBLY 1 Fully apply joint grease to wheel side joint Use joint grease in the tube included in spare part or joint grease 99000 25120 2 Fit wheel side boot on shaft Fill up inside of boot with joint grease of about 85 gram Before fixing boot band insert screwdriver into boot on joint side and allow air to enter boot so that air pressure in boot becomes the same as atmospheric pressure 3 Fixing boot band 4 Install boot onto drive shaft till its small diameter side fits to shaft groove and fix there with boot band 2 Boot band 5 Install cage to shaft CAUTION Install cage directing smaller outside diameter side to shaft end 6 Install circlip by using snap ring plier 1 Circlip 7 Apply grease to entire surface of cage Use joint grease in tube included in spare part or joint grease 99000 25120 4A2 6 FRONT DRIVE SHAFT SHAFT BEARING OIL SEAL 8 Insert cage into outer race and fit circlip into groove of outer race CAUTION Position opening of circlip a so that it will not be lined up with a ball 1 Circlip 9 Apply grease to inside of outer race and fit boot to outer race Fill up inside of boot with joint grease A Joint Grease 99000 25120 10 Fitting boot to outer race adjust so that measurements b and C become as indicated in figure Length b
47. in that they could affect the performance of vital parts and systems and or could result in major repair expense They must be replaced with one of the same part number or with an equivalent part if replacement becomes necessary Do not use a replacement part of lesser quality or substitute design Torque values must be used as specified during reassembly to as sure proper retention of all parts There is to be no welding as it may result in extensive damage and weakening of the metal e For the descriptions items not found in this section refer to the same section of the Service Manual mentioned in FOREWORD of this manual CONTENTS GENERAL DESCRIPTION TIRES This vehicle is equipped with following tire depending on vehicle specification P205 75 R15 1 64 or P215 65 R16 2 04 The tires are of tubeless type The tires are designed to operate satisfactorily with loads up to the full rated load capacity when inflated to the recommended inflation pressure Correcttire pressures and driving habits have an important influence on tire life Heavy cornering excessively rapid acceleration and unnecessary sharp braking increase tire wear WHEELS Standard equipment wheels are following steel wheels 15x 5 1 2 JJ 1 64 or 16 x 6 1 2 J 2 04 3F 2 WHEELS AND TIRES ON VEHICLE SERVICE TIRE MOUNTING AND DEMOUNTING Usetire changing machine to mount or demounttires Follow equip ment manufacturer s instructions Do not use han
48. inal B and its terminal to Black lead wire If motor rotates at a high revolution speed of 67 to 83 rpm it is proper 2 lesting automatic stop action a Connect 12 V battery terminal to terminal A of wiper mo tor and terminal to Black lead wire and let the motor turn b Disconnect terminal A from battery and let the motor stop c Connectterminal A and D with a jumper wire and connect terminal C to battery terminal Observe the motor turns once again then stops at a given position d Repeat a thru c several times and inspect if the motor stops at the given position every time Battery Wiper motor Red lead Black lead Jumper BODY SERVICE 9 1 SECTION 9 BODY SERVICE WARNING For vehicles equipped with Supplemental Restraint Air Bag System e Service on and around the air bag system components or wiring must be performed only by an autho rized SUZUKI dealer Refer to Air Bag System Components and Wiring Location View under Gener al Description in air bag system section in order to confirm whether you are performing service on or nearthe air bag system components or wiring Please observe all WARNINGS and Service Precau tions under On Vehicle Service in air bag system section before performing service on or around the air bag system components or wiring Failure to follow WARNINGS could result in unintentional activation of the system or could render the sy
49. iner should be held upright 5 When refrigerant container is emptied use following procedure to replace it with a new refrigerant container a Close low pressure valve b Replace empty container with a refrigerant container which has been charged with refrigerant When using refrigerant container tap valve use following procedure for replace ment i Retract needle and remove refrigerant container tap valve by loosening its plate nut ii Install previously removed refrigerant container tap valve to a new refrigerant container c Purge any air existing in center charging hose When using refrigerant container tap valve use following procedure to purge air i Once fully tighten refrigerant container tap valve and then loosen open plate nut slightly li Open low pressure valve of manifold gauge set a little iii As soon as refrigerant comes out with a hiss through a clearance between refrigerant container and tap valve tighten plate nut as well as manifold gauge set low pres sure valve iv Turn handle of tap valve clockwise so that its needle is screwed into the new container to make a hole for refriger ant flow AIR CONDITIONING OPTIONAL 1B 5 6 After the system has been charged with specified amount 350 4509 12 3 16 007 of refrigerant or when low and high pres sure gauges have indicated specified value below respectively close low pressure side valve of manifold gauge set Low pressure gau
50. ing and ohmmeter measure resistance of stator coil between clutch lead wire and ground If measured resistance is not within tolerance replace coil Standard resistance 3 9 4 3 at 20 C 68 F REMOVAL 1 Remove compressor from vehicle Refer to COMPRESSOR in this section 2 Fix armature plate with special tool A and remove armature plate bolt and washer Special Tool A 09991 06020 NOTE Do not reuse armature plate bolt 3 Using special tool B remove armature plate Special Tool B 09991 06030 1B 16 AIR CONDITIONING OPTIONAL 4 Remove shims from shaft 5 Using special tool C remove circlip Special Tool C 09900 06107 6 Remove magnet clutch lead wire clamp screw and remove magnet clutch read wire ground terminal 7 Remove magnet clutch with puller NOTE Be careful not to damage pulley when tapping magnet clutch 1 Puller 2 Compressor 8 Remove magnet clutch coil Special tool C 09900 06107 INSTALLATION 1 Install magnet clutch coil Protrusion on under side of coil ring must match hole in com pressor assembly to prevent movement ant correctly locate lead wire 2 Using special tool C install snap ring as shown Special Tool Snap ring Clutch coil C 09990 06107 Compressor assembly 3 Install clamp portion and ground terminal of lead wire AIR CONDITIONING OPTIONAL 1B 17 4 Install magnet clutch 1 Set magnet clutch squarel
51. ion e Tightening torque For any tightening torque other than those specified in text refer to torque specification table at the end of this section FRONT SUSPENSION 3D 9 TIGHTENING TORQUE SPECIFICATIONS 90N m 50 85 Num TEM ae TIT AGS vo nnt A iP wen REC LTEM E HUS AUI LE X mu un SU p DEC yep m a ERN Ts te F 4E wx Sa SIE pe E di etc a hi nd 85 Nm 127 Nm REAR SUSPENSION 1 SECTION 3E REAR SUSPENSION NOTE e All suspension fasteners are an important attaching part in that it could affect the performance of vital parts and systems and or could result in major repair expense They must be replaced with one of the same part number or with an equivalent part if replacement becomes necessary Do not use a replace ment part of lesser quality or substitute design Torque values must be used as specified during reas PE sembly to assure proper retention of this part e Never attempt to heat quench or straighten any suspension part Replace it with a new part or damage to the part may result e For the descriptions items not found in this section refer to the same section of the Service Manual mentioned in FOREWORD of this manual CONTENTS 3E 2 REAR SUSPENSION BN 1 Rear axle housing 2 Floor jack 2 gt Blank Absorber nut Upper support Rubber bush Lowe
52. iquid pipe LY AIR CONDITIONING OPTIONAL 1B 11 INSPECTION 1 Check evaporator fins for blockage If found clogged use com pressed air to clean the fins NOTE Do not use water for cleaning of evaporator 2 Check inlet and outlet fittings for crack or scratch Repair them as required ASSEMBLY AND INSTALLATION 1 Reverse removal sequence to install evaporator 2 Enable air bag system Refer to Enabling Air Bag System in Section 10B 3 Evacuate and charge system according to previously described procedure EXPANSION VALVE INSPECTION Refer to Troubleshooting Procedure Using Manifold Gauge Set in this section REMOVAL 1 Recover refrigerant by using recovery and recycling equipment Be sure to follow the instruction manual for the equipment The amount of compressor oil removed must be measured and the same amount added to the system 2 Remove front grill 3 Disconnect suction pipe and liquid pipe from evaporator Cool ing unit NOTE As soon as above hose and pipe are disconnected cap opened fittings so that moisture and dust may not enter cooling unit 4 Disconnect suction pipe and liquid pipe from suction hose and condenser outlet pipe 5 Remove pipe clamp then remove suction pipe and liquid pipe 1B 12 AIR CONDITIONING OPTIONAL 6 Remove expansion valve INSTALLATION 1 Reverse removal sequence to install expansion valve 2 Evacuate and charge system according to
53. is i FEDERER LY n m5 SEMEN Z BODY SERVICE 9 13 eM ILLILX IZ E a O x ri 2 compu Center floor Rear floor a 30 mm 1 18 in 1 Side body outer 2 Side sill inner 3 Main floor 4 Front fender A Apply undercoating PVC 400 um or more 5 Front wheel housing B Additional applying of under coating 6 Frame for 5 door vehicle without splush guard 7 Dash panel 8 9 Apply PVC chip resistant material 200 um or more 9 14 BODY SERVICE PA v at SSK WON PRES RS Yi Le rie H n 2 AC ENFAN d 240 mm 9 45 in 20 mm 0 79 in gt 40 mm 1 57 in gt oocoomv Black paint 7 A F Vip CZ ve Es f i c E LA SZ al m BODY SERVICE 9 15 CONVERTIBLE TOP CANVAS TOP AND TOPBOW FRAMES Removal 1 Open canvas to referring to Owner s Manual 2 Remove fording top and rear canvas top 3 Remove topbow bracket cover 1 Topbow center flame 2 Bracket cover 4 Remove topbow center frame 5 Remove topbow front frame 1 Topbow front frame Installation Install in reverse order of removal procedure 9 16 BODY SERVICE EXTERIOR AND INTERIOR TRIM FLOOR CARPET Dash side trim Front
54. ition switch is turned to the LOCK position and the negative cable is disconnected from the battery Otherwise the system may be activated by reserve energy in the Sensing and Diagnostic Module SDM NOTE e When inspecting and servicing vehicle equipped with ABS be sure to refer to section 5E1 first e All brake fasteners are important attaching parts in that they could affect the performance of vital parts and systems and or could result in major repair expense They must be replaced with one of same part number or with an equivalent part if replacement becomes necessary Do not use a replacement part of lesser quality or substitute design Torque values must be used as specified during reassembly to as sure proper retention of all parts There is to be no welding as it may result in extensive damage and weakening of the metal e For the descriptions items not found in this section refer to the same section of the Service Manual mentioned in FOREWORD of this manual CONTENTS CHECK AND ADJUSTMENT Fluid Pressure Test TIGHTENING TORQUE SPECIFICATIONS 5 2 BRAKES 1 Air bleeder plug 2 Weight 3 Attachment CHECK AND ADJUSTMENT FLUID PRESSURE TEST if equipped with LSPV Test procedure for LSPV assembly is as follows Before testing confirm the following e Fuel tank is filled with fuel fully e Vehicle is equipped with spare tire tools jack and jack handle 1 2 E Stop vehicle on level floor and
55. knuckle and wheel hub comp while lowering jack 15 Remove coil spring 3D 4 FRONT SUSPENSION INSTALLATION Reverse removal procedure to install coil spring NOTE Upper and lower diameters of coil spring are different Bring larger diameter end at bottom and set its open end in place on spring seat 1 Spring seat e Be sure to use specified torque for tightening each fastener Refer to torque specification chart at the end of this section As for ball stud nut be sure to use new nut Tighten tie rod end nut with pushing ball stud to upper side so as not ball stud to be rotated Apply lithium grease to front drive shaft washer and front wheel spindle outer Grease 99000 25010 When installing circlip to drive shaft utilize screw hole in drive shaft to pull it out and bring large diameter of circlip at right as shown 1 Circlip 2 Large diameter When installing axle shaft drive flange to wheel hub apply sealant to mating surface of axle shaft drive flange and tighten flange bolt to specified torque A Sealant 99000 31090 Tightening Torque a 48 N m 4 8 kg m 35 0 Ib ft 1 Axle shaft drive flange 2 Bolt 1 Front wheel speed sensor FRONT SUSPENSION 3D 5 Check that no foreign material is attached to sensor and rotor Install wheel soeed sensor and its harness clamp Tightening Torque a 10 N m 1 0 kg m 7 5 Ib ft b 23 N m 2 3 kg m 17 0 Ib ft CAU
56. lant 99000 31090 Tightening Torque b 48 N m 4 8 kg m 35 0 Ib ft CAUTION e To prevent breakage of boots wheel side and differen tial side be careful not to bring them into contact with other parts when installing drive shaft assembly e Do not pull housing of differential side joint If housing is pulled it may be detached from drive shaft e Apply chassis grease to spline of sliding yoke e Fill specified differential gear oil into differential case to specified level 1 Drive shaft flange bolt and nut 2 Axle shaft drive flange BRAKES 5 1 SECTION 5 BRAKES WARNING For vehicles equipped with Supplemental Restraint Air Bag System e Service on and around the air bag system components or wiring must be performed only by an autho rized SUZUKI dealer Refer to Air Bag System Components and Wiring Location View under Gener al Description in air bag system section in order to confirm whether you are performing service on or nearthe air bag system components or wiring Please observe all WARNINGS and Service Precau tions under On Vehicle Service in air bag system section before performing service on or around the air bag system components or wiring Failure to follow WARNINGS could result in unintentional activation of the system or could render the system inoperative Either of these two conditions may result in severe injury e Technical service work must be started at least 90 seconds after the ign
57. le to 60A type generator described in the same section of the Service Manual mentioned in FOREWORD of this manual CONTENTS 6H 2 CHARGING SYSTEM GENERAL DESCRIPTION GENERATOR 70 A type 1 Pulley 6 Field coil B Generator output Battery terminal 2 Pulley nut 7 Regulator E Ground 3 Rotor fan 8 Brush IG Ignition terminal 4 Stator coil 9 Front housing L Lamp terminal 5 Stator core 10 Rear housing a E GUE Gy GE dE 1 Generator with regulator ass y 5 Field coil rotor coil 2 C regulator 6 Charge indicator light 3 Stator coil 7 Main switch 4 Diode 8 Battery CHARGING SYSTEM 6 3 SPECIFICATIONS BATTERY NOTE The battery used in each vehicle is one of the following three types depending on specification GP26R Cold Cranking Ampere Rated Capacity AH SHR 12 Vols GENERATOR NOTE The generator used in each vehicle is one of the following two types depending on specification RR Setting voltage 14 4 to 15 0 V Permissible ambient 30 to 90 C 22 to 194 F temperature Polarity Negative ground Clockwise viewed from pulley side AUTOMATIC TRANSMISSION 4 7B1 1 SECTION 7B1 AUTOMATIC TRANSMISSION 4 A T WARNING For vehicles equipped with Supplemental Restraint Air Bag System e Service on and around the air bag system components or wiring must be performed only by an autho
58. ler Refer to Air Bag System Components and Wiring Location View under Gener al Description in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring Please observe all WARNINGS and Service Precau tions under On Vehicle Service in air bag system section before performing service on or around the air bag system components or wiring Failure to follow WARNINGS could result in unintentional activation of the system or could render the system inoperative Either of these two conditions may result in severe injury e Technical service work must be started at least 90 seconds after the ignition switch is turned to the LOCK position and the negative cable is disconnected from the battery Otherwise the system may be activated by reserve energy in the Sensing and Diagnostic Module SDM NOTE For the descriptions items not found in this section refer to the same section of Service Manual men tioned in FOREWORD of this manual CONTENTS 8C 2 INSTRUMENTATION DRIVER INFORMATION GENERAL DESCRIPTION COMBINATION METER A12 11 9 9 B13 B2 B3 B4 B5 B7 B6 O O O O QU CE E HN MN UN H T inant 909090 HHEH aa VE 00 0 0 O om al Q Q O Q O CO C C B12 C2 B11 B10 A13 B8 C1 A10 A15 A16 A5 C8 C7 C6 C5 C3 C4 B9 B1 NOTE Terminal arrangement of couple
59. low proce dures described in SECTION 10B Failure to follow proper procedures could result in possible air bag system activa tion personal injury damage to parts or air bag system being unable to activate when necessary elf the air bag system and another vehicle system both need repair SUZUKI recommends that the air bag system be repaired first to help avoid unintended air bag system activation e Do not modify the steering wheel dashboard or any other air bag system components Modifications can adversely affect air bag system performance and lead to injury e If the vehicle will be exposed to temperatures over 93 C 200 F for example during a paint baking process re movethe air bag system components beforehand to avoid component damage or unintended air bag system activa tion Air bag wire harness Contact coil Passenger air bag Driver air bag inflator inflator module module SDM Seat belt pretensioner DLC if equipped DIAGNOSIS e When troubleshooting air bag system be sure to follow DIAGNOSIS in SECTION 10B Bypassing these proce dures may result in extended diagnostic time incorrect diag nosis and incorrect parts replacement e Never use electrical test equipment other than that specified in this manual WARNING Never attempt to measure the resistance of the air bag in flator modules driver and passenger and seat belt preten tioners driver and passenger It is very dang
60. loyment Otherwise personal injury may result Never dispose of live undeployed air bag inflator mod ules driver and passenger If disposal is necessary be sure to deploy them according to deployment procedures described in SECTION 10B before disposal The air bag inflator module immediately after deploy ment is very hot Wait for at least half an hour to cool it off before proceeding the work e After an air bag inflator module has been deployed the surface of the air bag may contain a powdery residue This powder consists primarily of cornstarch used to lubri cate the bag as it inflates and by products of the chemical reaction As with many service procedures gloves and safety glasses should be worn 1 Slit on workbench 2 Workbench vise 3 Lower mounting bracket 4 GENERAL INFORMATION Exhaust hole WARNING SDM e During service procedures be very careful when handling a Sensing and Diagnostic Module SDM Never strike or jar the SDM Never power up the air bag system when the SDM is not rigidly attached to the vehicle All SDM and mounting bracket fasteners must be carefully torqued and the arrow must be pointing toward the front of the vehicle to ensure proper operation of the air bag system The SDM could be activated when powered while not rigid ly attached to the vehicle which could cause deployment and result in personal injury WARNING Driver and Passenger Seat Belt Pretensioners e
61. m 1 ft or more it should be replaced Check retractor assembly with seat belt pretensioner appearance visually for following symptoms and if any one of them is applicable replace it with a new one as an assembly e Pretensioner has activated e here is a crack in seat belt pretensioner retractor assembly e Wire harness or connector is damaged e Seat belt pretensioner retractor assembly is damaged or a strong impact e g dropping was applied to it AIR BAG SYSTEM 10 1 SECTION 10B AIR BAG SYSTEM WARNING e Service on or around the air bag system components or wiring must be performed only by an autho rized SUZUKI dealer Please observe all WARNINGS and Service Precautions under On Vehicle Service in this section before performing service on or around the air bag system components or wiring Failure to follow WARNINGS could result in unintended activation of the system or could ren der the system inoperative Either of these two conditions may result in severe injury e The procedures in this section must be followed in the order listed to disable the air bag system tem porarily and prevent false diagnostic trouble codes from setting Failure to follow procedures could result in possible activation of the air bag system personal injury or otherwise unneeded air bag sys tem repairs CAUTION When fasteners are removed always reinstall them at the same location from which they were re moved If a fastene
62. n motor relay B EVAP canister 3 Power steering pressure switch if equipped C Data link connector if equipped c EVAP canister purge valve D Combination meter 4 Heated oxygen sensor if equipped d Ignition coil assemblies 5 Monitor connector e Main relay 6 ABS control module if equipped f Fuel pump relay 7 Camshaft position sensor CMP sensor g Malfunction indicator lamp 8 ECT sensor CHECK ENGINE light 9 TP sensor h Injectors 10 Battery i EGR valve if equipped 11 CO adjusting resistor if equipped NOTE Above figure shows left hand steering vehicle For right hand steering vehicle parts with are installed at the other side 6E1 4 ENGINE AND EMISSION CONTROL SYSTEM G16 J20 ENGINE DIAGNOSIS The engine and emission control system in this vehicle are con trolled by ECM PCM ECM PCM has an On Board Diagnostic sys tem which detects a malfunction in this system When diagnosing troubles be sure to have full understanding of the outline of On Board Diagnostic System and each item in Precau tion in Diagnosing Trouble and execute diagnosis according to Engine Diagnostic Flow Table in Section 6 ON BOARD DIAGNOSTIC SYSTEM ECM POCM performs on board diagnosis self diagnosis on the system and operates CHECK ENGINE lamp malfunction indica tor lamp as follows e Malfunction indicator lamp CHECK ENGINE light lights when the ignition switch is turned ON butthe engine at stop
63. nnermost end of side body installation section 1145 mm 45 08 in 1017 mm 40 04 in 1078 mm 42 44 in 57 44 in 548 mm 21 57 in 1338 mm 52 68 in 956 mm 37 64 in Hole to hole distance 1 b f c g d e 1154 mm 45 43 in 1150 mm 45 28 in 1165 mm 45 87 in 1142 mm 44 96 in 1246 mm 49 06 in 1146 mm 45 12 in BODY SERVICE 9 5 Hole in door upper hinge at rear Hole in door lower hinge at rear Trim installation clip hole 7 jig hole Scuff installation hole rearmost end Door striker lower section installation hole F seat belt installation hole 9 6 BODY SERVICE Hole to hole distance a a 1134 mm a f a g a f a g b d f f 1324 mm 1029 mm 1112 mm 43 78 in 44 65 in 31 34 in 45 51 in 32 44 in mm 96 mm 1156 mm 824 mm 1229 mm 48 39 in 52 13 in 60 79 in 40 51 in 1544 mm AM o A m m a Trim installation clip hole Installation hole in uppermost part of upper hinge Installation hole in outside part of lower hinge Installation hole in uppermost part of rear gate striker e Installation hole in outer upper section of R COMB R L lamp Innermost end of rear floor tail member installation section 9 Garnish installation clip hole a b 9 REAR SEAT Seat cushion
64. nt breakage of boots wheel side and differential side be careful not to bring them into contact with other parts when removing drive shaft assembly 1 Differential side joint 2 Tire lever 3 Front differential assembly Remove drive shaft thrust washer from drive shaft and remove drive shaft oil seal as shown in figure CAUTION Be careful not to cause damage to drive shaft joint 1 Oil seal 4A2 4 FRONT DRIVE SHAFT SHAFT BEARING OIL SEAL DISASSEMBLY 1 Remove boot band of differential side joint 2 Slide boot toward the center of shaft and remove snap ring from outer race then take shaft out of outer race 2 Snap ring 3 Remove circlip and then cage 4 Remove inside and outside boots from shaft CAUTION Do not disassemble wheel side joint outboard joint If any malcondition is found in joint replace it as assem bly e Do not disassemble ball joint of differential side joint If any malcondition is found in ball joint replace differ p ring plier 3 Cage ential side joint assembly INSPECTION e Check boots for breakage or deterioration Replace them as nec essary e Check circlip snap ring and boot bands for breakage or deforma tion Replace as necessary CLEANING e Wash disassembled parts except boots in degreaser After washing dry parts completely by blowing air e Clean boots with cloth DO NOT wash boots in degreaser such as gasoline or kerosene etc Was
65. o 9ggoosc gcao e 9090o089 oocctogtttood oOooooco5SooongsGc _ _ VIEW W BODY SERVICE 9 11 Be free from protrude of sealant outside from this line VIEW FF GG GG VIEW EE Sealant width W more than 5 mm A Apply sealant 9 12 BODY SERVICE UNDERCOATING ANTI CORROSION COMPOUND APPLICATION AREA Canvas top model EI L VS Z IV ES z SS SESNSNNNSNANNNNN YY NEUE NUN E Q M iz Y HIZ EN BA ENS fi Li E n y eee i uu e D Wim VIEW Z 200 7 87 1 Side body outer b 100 mm 3 94 in 2 Side sill inner 3 Frame 4 Main floor A Apply rust proof wax hot wax 50 um or more 5 Rearfender B Apply rust proof wax high viscosity wax 50 um or more 6 Rear wheel housing 7 Center floor TET er i RO 9 sd LL y Tru i ant ek pie vy TZ AES ZZZ VS P FC ZA OANA VEM IT gt 2 7 2 231 A NA S BAAL Ur AA STU 0 EE IL IEE BATA OW T HAA Uf 2 2 LAT 4 E f 090 UA A ZZ l
66. on Automatic Transmission Transfer and 99501 65000 TABLE OF CONTENTS SECTION GENERAL INFORMATION General Information HEATING AND AIR CONDITIONING Air Conditioning STEERING SUSPENSION WHEELS AND TIRES Power Steering P S System Air Bag Steering Wheel and Column 3C1 Front Suspension Rear Suspension _ WhedandTres s DRIVE SHAFT PROP SHAFT iarsa Bearing Oil Seal BRAKES 0 0 5 _ Cylinder ENGINE General Information and Diagnosis EM Engine and Emission Control System SFI for G16 J20 Charging System 6H TRANSMISSION CLUTCH AND DIFFERENTIAL Automatic Transmission BODY ELECTRICAL SYSTEM m 00 8 O Instrumentation Driver 8C Information Windows Mirrors Security and Lock BODY SERVICE 9 RESTRAINT SYSTEM Seat Belt Air Bag System 10B GENERAL INFORMATION 0 1 SECTION 0A GENERAL INFORMATION NOTE For the descriptions items not found in this section refer to the same section of the Service Manual men tioned in FOREWORD of this manual CONTENTS 0A 2 GENERAL INFORMATION PRECAUTIONS PRECAUTION FOR VEHICLES EQUIPPED WITH A SUPPLEMENTAL RESTRAINT AIR BAG SYSTEM WARNING e The configuration of air bag system parts are as shown in the figure When it is necessary to service remove rein stall and inspect these parts be sure to fol
67. one of refrigerant compressor oil and component parts is interchangeable between two types of A C one using refrigerant CFC 12 R 12 and the other using refrigerant HFC 134a R 134a Be sure to check which refrigerant is used before any service work including inspection and mainte nance For identification between these two types refer to the description in page 1B 2 When replenishing or changing refrigerant and compressor oil and when replacing parts make sure that the material or the part to be used is appropriate to the A C installed in the vehicle being serviced Use of incorrect one will result in leakage of refrigerant damage in parts or other faulty condition NOTE For the descriptions items not found in this section refer to the same section of the Service Manual men tioned in FOREWORD of this manual CONTENTS Major Components and Refrigerant Flow of Air Conditioning 1B 2 AIR CONDITIONING OPTIONAL GENERAL DESCRIPTION Whether the A C in the vehicle being serviced uses R 134a or R 12 is indicated on LABEL on the compressor Also it can be checked 1 Compressorlabe the shape of the service charge valve 2 Service valve MAJOR COMPONENTS AND REFRIGERANT FLOW OF AIR CONDITIONING SYSTEM t t 5 Se 285 xc XC 7 Cad a d 264 AT TORTE e 3b e T0277 777277 7 1 unu UI O1 DF B Mina Noon STE almpiicese X 22 Je i Magne
68. place approximately about 200 kg 441 lbs weight on rear housing so that rear axle weighs 800 kg 1764 Ib Rear axle weight L 800 kg 1764 Ib Install special tool to front and rear brake NOTE Special tool should be connected to breather of front driv er s side brake and rear brakes Special Tool Front brake A 09956 02310 C 55473 82030 Air bleeder plug supplied as a spare part Rear brake A 09956 02310 B 09952 36310 C 55473 82030 Air bleeder plug supplied as a spare part NOTE Special tool B is used instead of thread diameter 10 mm attachment of special tool A So remove the attachment from A and install B as shown in figure Depress brake pedal gradually till fluid pressure of front brake becomes as specified below and check corresponding pressure of rear brake then It should be within specification given below 8 000 kPa 6 000 7 300 kPa 80 kg cm 60 73 kg cm 1 138 psi 853 1 038 psi As done above apply 100 kg cm pressure to front brake and checkthat rear brake pressure then is within specification as giv en below 10 000 kPa 6 500 8 000 kPa 100 kg cm 65 80 kg cm 1 422 psi 924 1 138 psi BRAKES 5 3 4 If rear brake pressure is not within specification adjust it by changing stay A position as follows Tightening Torque a 23 N m 2 3 kg m 17 0 Ib ft e f rear brake pressure is higher than specification move stay A to dir
69. r bag inflator module Steering wheel Steering wheel nut Contact coil and combination switch assembly Steering column upper cover Steering column lower cover Steering column assembly Steering lock assembly Steering column hole cover Steering shaft joint Steering lower shaft assembly Adjustable steering column release lever Steering column lower seal Cap AIR BAG STEERING WHEEL AND COLUMN 3 1 3 ON VEHICLE SERVICE DRIVER AIR BAG INFLATOR MODULE WARNING When handling an air bag inflator module be sure to read Service Precautions under On Vehicle Service in SEC TION 10B and observe each instruction Failure to follow them could cause a damage to the air bag inflator module or result in personal injury REMOVAL 1 Disconnect negative battery cable at battery terminal 2 Disable air bag system Refer to Disabling Air Bag System un der Service Precautions in SECTION 10B 3 Remove mounting bolt hole caps 2pcs 4 Loosen 2 bolts mounting driver air bag inflator module till it turns freely pull them out and fix them to bolt clamps 5 Remove air bag inflator module from steering wheel 1 Mounting bolt 6 Remove driver air bag inflator module yellow connector and horn connector from steering wheel 7 Disconnect driver air bag inflator module yellow connector of driver air bag inflator module and horn connector as shown in the figure i Release lockin
70. r needs to be replaced use the correct part number fastener for that application If the correct part number fastener is not available a fastener of equal size and strength or stronger may be used Fasteners that are not reused and those requiring thread locking compound will be called out The correct torque value must be used when installing fasteners that require it If the above condi tions are not followed parts or system damage could result NOTE For the descriptions items not found in this section refer to the same section of the Service Manual men tioned in FOREWORD of this manual CONTENTS ON VEHICLE SERVICE Service Precautions and Storage 10B 2 AIR BAG SYSTEM 1 Webbing 2 Retractor assembly 2 1 Seat belt pretensioner 2 2 Seat belt pretensioner harness ON VEHICLE SERVICE SERVICE PRECAUTIONS HANDLING AND STORAGE LIVE INACTIVATED SEAT BELT PRETENSIONERS opecial care is necessary when handling and storing a live inacti vated seat belt pretensioners Also when the seat belt pretensioners activate gas is generated and the seat belt is retracted into the retractor quickly Note therefore that if they activate accidentally the seat belt pre tensioners and other object s around them may be thrown through the air WARNING Never attempt to measure the resistance of the seat belt pre tensioners It is very dangerous as the electric current from the tester may activate pretensioner
71. r support Shock absorber Body Outside ON VEHICLE SERVICE SHOCK ABSORBER The shock absorber is non adjustable non refillable and cannot be disassembled The only service the shock absorber requires is replacement when it has lost its resistance is damaged or leaking fluid REMOVAL 1 Hoist vehicle and remove rear wheel 2 Support rear axle housing by using floor jack to prevent it from lowering 3 Remove absorber nut 4 Remove lower mounting bolt 5 Remove shock absorber INSTALLATION 1 Install shock absorber Refer to figure for proper installing direc tion of lower mounting bolt 2 Remove floor jack 3 Lower hoist 4 Tighten nuts to specified torque NOTE e Tighten lower nut with vehicle off hoist and in non loaded condition e Use new absorber nut Tightening Torque a 29 N m 2 9 kg m 21 0 Ib ft b 85 N m 8 5 kg m 61 5 Ib ft REAR SUSPENSION 3E 3 XT LOWER ROD Wa REMOVAL f To 1 Hoist vehicle and remove rear wheel jl 2 Support rear axle housing by using floor jack g 1 Axle housing EE f 2 Floor jack 3 Remove lower rod front mount bolt 1 Lower rod 2 Front mount bolt 4 Remove lower rod rear mount bolt 1 Lower rod 2 Rear mount nut INSTALLATION Body side Axle side 1 Install lower rod to chassis frame and axle housing referring to figure for proper installing direction of bolts Nuts should not be tightened Lower rod EE 2
72. r viewed from harness side Coupler A Coupler B Coupler C 72121212 5 718 135 Coupler Coupler B Coupler C 1 Blank 1 door switch driver side 1 To ground B 2 Blank KNEE 2 To shift switch A T vehicle only G BI 2 To ECM PCM for A T vehicle 3 To ignition switch B W To shift switch A T vehicle only 2 G O 3 To ignition switch V R 4 Blank 4 To shift switch A T vehicle only 0 Y G 4 To brake fluid level switch H B 5 To ABS control module BI O 5 To shift switch A T vehicle only O BI 5 To parking brake switch V 6 To POM A T vehicle only Gr 6 To shift switch A T vehicle only P O G 6 To seat belt switch if equipped Gr R 7 Blank E 7 To shift switch A T vehicle only R 7 To generator W R 8 To VSS BI Y 8 To ground B 8 To oil pressure switch 9 To combination switch G R 9 To PCM A T vehicle only W B 9 To combination switch R Y 10 To SDM Y G 10 To ECT sensor Y W 10 Blank LS 11 To main fuse W BI 11 To fuel level gauge BI W 12 To fuse box W 12 To ground B Y 13 To combination switch H 13 To combination switch G Y 14 Blank 15 To ECM PCM for A T vehicle V Y 16 To 4WD controller O B WINDOWS MIRRORS SECURITY AND LOCKS 80 1 SECTION 8D WINDOWS MIRRORS SECURITY AND LOCKS WARNING For vehicles equipped with Supplemental Restraint Air Bag System e Service on and around the air bag system components or wiring must
73. regardless of the condition of Engine and emission control system This is only to check the malfunction indicator lamp CHECK ENGINE light bulb and its circuit e f the areas monitored by ECM PCM is free from any trouble after the engine start while engine is running malfunction indicator lamp CHECK ENGINE light turns OFF e When ECM POM detects a trouble which has occurred in the areas it makes malfunction indicator lamp CHECK ENGINE light turn ON while the engine is running to warn the driver of such occurrence of trouble and at the same time it stores the exact trouble area in ECM PCM back up memory PRECAUTIONS IN DIAGNOSING TROUBLES e Before identifying diagnostic trouble code don t disconnect cou plers from ECM PCM battery cable from battery ECM PCM ground wire harness from engine Such disconnection will erase memorized trouble in ECM PCM memory e Be sure to read Precautions for Electrical Circuit Service in Sec tion OA before inspection and observe what is written there e ECM POM replacement When substituting a known good ECM POCM check for following conditions Neglecting this check may cause damage to known good ECM PCM Resistance value of all relays actuators is as specified re spectively sensor and fuel tank pressure sensor if equipped are in good condition and none of power circuits of these sensors is shorted to ground ENGINE AND EMISSION CONTROL SYSTEM G16 J20 ENGINE 6
74. ring wheel by utilizing the hydraulic pressure generated by the power steering P S pump which is driven by the engine It is an integral type with the rack and pinion gears and the control valve unit hydraulic pressure cylinder unit all built in the steering gear box 1 Power steering gear box 2 Power steering pump 3 Oil tank Tie rod Steering rack Boot Mark Tie rod lock washer Tie rod Steering rack Aluminium plate Vise 1 Tie rod lock washer POWER STEERING P S SYSTEM 3B1 3 ON VEHICLE SERVICE RACK BOOT TIE ROD LH STEERING VEHICLE REMOVAL 1 Remove steering gear case refer to POWER STEERING GEAR BOX ASSEMBLY REMOVAL 2 Forease of adjustment after installation make marking of tie rod end lock nut position of tie rod thread 3 Loosen tie rod end lock nut and remove tie rod end 4 Remove boot band and clip 5 Remove boot from tie rod 6 Unbend washer 2 places and remove tie rod from rack INSTALLATION 1 Install new tie rod lock washer and tie rod to rack 2 Tighten tie rod ball nut to specified torque Tightening Torque a 85 N m 8 5 kg m 61 5 Ib ft 3 Bend lock washer 2 place at the flat part of tie rod ball nut 3B1 4 POWER STEERING P S SYSTEM 4 Apply grease to A indicated in figure 5 Position boot properly in grooves of gear case and tie rod Check to ensure that boot is free from twist and dent 6 Fasten boot with new clamp and clip se
75. rt of air bag system components Be sure to follow the instruc tions e After vehicle is completely repaired perform Air Bag Diagnostic System Check described in Diagnosis in SECTION 10B AIR CONDITIONING OPTIONAL 1 1 SECTION 1B 2 AIR CONDITIONING OPTIONAL WARNING For vehicles equipped with Supplemental Restraint Air Bag System Service on and around the air bag system components or wiring must be performed only by an autho rized SUZUKI dealer Refer to Air Bag System Components and Wiring Location View under Gener al Description in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring Please observe all WARNINGS and Service Precau tions under On Vehicle Service in air bag system section before performing service on or around the air bag system components or wiring Failure to follow WARNINGS could result in unintentional activation of the system or could render the system inoperative Either of these two conditions may result in severe injury Technical service work must be started at least 90 seconds after the ignition switch is turned to the LOCK position and the negative cable is disconnected from the battery Otherwise the system may be activated by reserve energy in the Sensing and Diagnostic Module SDM CAUTION The air conditioning system of this vehicle uses refrigerant HFC 134a R 134a N
76. rvice in air bag system section before performing service on or around the air bag system compo nents or wiring Failure to follow WARNINGS could result in unintentional activation of the system or could render the system inoperative Either of these two conditions may result in severe injury e The procedures in this section must be followed in the order listed to disable the air bag system tem porarily and prevent false diagnostic trouble codes from setting Failure to follow procedures could result in possible activation of the air bag system personal injury or otherwise unneeded air bag sys tem repairs CAUTION When fasteners are removed always reinstall them at the same location from which they were re moved If a fastener needs to be replaced use the correct part number fastener for that application If the correct part number fastener is not available a fastener of equal size and strength or stronger may be used Fasteners that are not reused and those requiring thread locking compound will be called out The correct torque value must be used when installing fasteners that require it If the above proce dures are not followed parts or system damage could result NOTE For the descriptions items not found in this section refer to the same section of the Service Manual men tioned in FOREWORD of this manual CONTENTS 3C1 2 AIR BAG STEERING WHEEL AND COLUMN 10 GENERAL DESCRIPTION io En de po To Driver ai
77. se parts beforehand e When handling the air bag inflator modules driver and passenger seat belt pretensioners driver and passen ger or SDM be careful not to drop it or apply an impact to it If an excessive impact was applied e g dropped from a height of 91 4 cm 3 feet or more never attempt disas sembly or repair but replace it with a new one e When grease cleaning agent oil water etc has got onto air bag inflator modules driver and passenger or seat belt pretensioners drive and passenger wipe off im mediately with a dry cloth e Air bag wire harness can be identified easily as it is cov ered with a yellow protection tube Be very careful when handling it e When an open in air bag wire harness damaged wire har ness connector or terminal is found replace wire har ness connectors and terminals as an assembly e Do not apply power to the air bag system unless all com ponents are connected or a diagnostic chart requests it as this will set a diagnostic trouble code e Never use air bag system component parts from another vehicle e When using electric welding be sure to temporarily dis able air bag system referring to Disabling Air Bag Sys tem described in Service Precautions under On Ve hicle Service in SECTION 10B e Never expose air bag system component parts directly to hot air drying or baking the vehicle after painting or flames e WARNING CAUTION labels are attached on each pa
78. side sill scuffs Center pillar inner lower trim c Rear side sill scuff Fastener Side sill scuff Rear quarter lower trim 1 Front floor carpet 2 Luggage floor carpet 3 Dash panel insulation FRONT FLOOR CARPET REMOVAL 1 Remove front seats and rear seat cushions 2 Remove seat belt lower anchor bolt 3 Remove dash side trims front side sill scuffs 5 door and 3 door model center pillar inner lower rims 5 door and 3 door model rear side sill scuffs 5 door and 3 door model side sill scuffs Canvas top model and rear quarter lower trim 4 Remove parking brake lever cover console box and console box front extension 5 Remove front floor carpet INSTALLATION Reverse removal sequence to install front floor carpet noting fol lowing point e When tightening seat belt anchor bolt refer to Section 10A FRONT SEAT BELT WITHOUT PRITENSIONER for tightening torque BODY SERVICE 9 17 ROOF TRIM REMOVAL 1 Remove canvas top Remove rear topbow 3 Remove side body garnishes Remove luggage mat end garnish Remove assistant grips 6 Remove sunshade assemblies Remove sunshade hooks Remove front topbow locks Remove canvas top snaps 10 Remove front seat belts Remove front pillar trims Remove rear side inner lower trims 13 Remove rear side inner upper trims Disconnect room light connector and remove room light har ness clamp 15 Remove roof trim
79. stem inoperative Either of these two conditions may result in severe injury e Technical service work must be started at least 90 seconds after the ignition switch is turned to the LOCK position and the negative cable is disconnected from the battery Otherwise the system may be activated by reserve energy in the Sensing and Diagnostic Module SDM e When body servicing if shock may be applied to air bag system component parts remove those parts beforehand Refer to Section 10B NOTE e For the descriptions items not found in this section refer to the same section of Service Manual men tioned in FOREWORD of this manual e Fasteners are important attaching parts in that they could affect the performance of vital components and systems and or could result in major repair expense They must be replaced with one of the same part number of with an equivalent part if replacement becomes necessary Do not use a replacement part of lesser quality or substitute a design Torque values must be used as specified during reassembly to assure proper retention of these parts CONTENTS 9 2 BODY SERVICE BODY STRUCTURE FRONT FENDER Front fender Front fender lining Fender attaching bolts Fender lining attaching screws REMOVAL 1 Remove front bumper 2 Remove fender splush guard H25 engine 3 Remove front fender lining 4 Remove front fender INSTALLATION 1 Remove pad from side body and or fender usin
80. t clutch nm Hoo Me LLLA Recois K State of Refrigerant Dual pressure switch LL zz Liquid Expansion valve Evaporator Vapor Blower motor IRE es Condenser Heater core petisse Cooling air Dryer Wat m i M a DONDAN AIR CONDITIONING OPTIONAL 1B 3 COMPONENT LOCATION IN ENGINE ROOM G16 LH steering vehicle 8 1 Liquid pipe 6 Compressor delivery hose 2 Compressor suction hose 7 Compressor 3 Dual pressure switch 8 Suction pipe J20 LH steering vehicle 4 Condenser outlet pipe 9 High pressure service valve 5 Condenser 10 Low pressure service valve 10 8 1B 4 AIR CONDITIONING OPTIONAL G16 LH steering vehicle shown 1 Manifold gauge set 2 High pressure side Delivery side hose 3 Low pressure side Suction side pipe Needle Plate nut Refrigerant container Handle RECOVERY EVACUATION AND CHARGING PROCEDURE OF CHARGING 1 Make sure that hoses are routed properly after evacuating the system 2 Connect the manifold gauge set in position Thus open refriger ant container valve to purge the charging line Then open the low pressure side valve WARNING Make sure that high pressure side valve is closed se curely 3 Start engine and keep engine speed at 1 000 r min Then oper ate air conditioning 4 Charge A C system with refrigerant in vapor state At this time refrigerant conta
81. vice in air bag system section before performing service on or around the air bag system components or wiring Failure to follow WARNINGS could result in unintentional activation of the system or could render the system inoperative Either of these two conditions may result in severe injury e Technical service work must be started at least 90 seconds after the ignition switch is turned to the LOCK position and the negative cable is disconnected from the battery Otherwise the system may be activated by reserve energy in the Sensing and Diagnostic Module SDM e The procedures in this section must be followed in the order listed to disable the air bag system tem porarily and prevent false diagnostic trouble codes from setting Failure to follow procedures could result in possible activation of the air bag system personal injury or otherwise unneeded air bag sys tem repairs CAUTION When fasteners are removed always reinstall them at the same location from which they were re moved If a fastener needs to be replaced use the correct part number fastener for that application If the correct part number fastener is not available a fastener of equal size and strength or stronger may be used Fasteners that are not reused and those requiring thread locking compound will be called out The correct torque value must be used when installing fasteners that require it If the above proce dures are not followed parts or system damage could result
82. whether you are performing service on or near the air bag system components or wiring Please observe all WARNINGS and Service Precau tions under On Vehicle Service in air bag system section before performing service on or around the air bag system components or wiring Failure to follow WARNINGS could result in unintentional activation of the system or could render the system inoperative Either of these two conditions may result in severe injury e Technical service work must be started at least 90 seconds after the ignition switch is turned to the LOCK position and the negative cable is disconnected from the battery Otherwise the system may be activated by reserve energy in the Sensing and Diagnostic Module SDM NOTE e All brake fasteners are important attaching parts in that they could affect the performance of vital parts and systems and or could result in major repair expense They must be replaced with one of same part number or with an equivalent part if replacement becomes necessary Do not use a replacement part of lesser quality or substitute design Torque values must be used as specified during reassembly to as sure proper retention of all parts There is to be no welding as it may result in extensive damage and weakening of the metal e For the descriptions items not found in this section refer to the same section of the Service Manual mentioned in FOREWORD of this manual CONTENTS 5A 2 BRAKES PIPE HOSE MAS
83. y over clutch installation boss 2 Place special tool D onto clutch bearing Ensure that edge rests only on inner race of bearing 3 Install snap ring Special Tool D 09991 06010 CAUTION Be careful not to scratch bearing seal 5 Adjust clearance between armature plate and magnet clutch by putting shim on compressor shaft Standard clearance 0 3 0 5 mm 0 012 0 02 in 6 Tighten new armature plate nut as specified below Tightening Torque a 14 N m 1 4 kg m 10 5 Ib ft Special Tool A 09991 06020 1 Armature plate 1B 18 AIR CONDITIONING OPTIONAL SPECIAL TOOLS 09900 06107 Snap ring pliers 09991 06010 09991 06020 09991 06030 Opening type Magnet clutch pulley installer Armature plate spanner Armature plate remover POWER STEERING P S SYSTEM 3B1 1 SECTION 3B1 POWER STEERING P S SYSTEM WARNING For vehicles equipped with Supplemental Restraint Air Bag System e Service on and around the air bag system components or wiring must be performed only by an autho rized SUZUKI dealer Refer to Air Bag System Components and Wiring Location View under Gener al Description in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring Please observe all WARNINGS and Service Precau tions under On Vehicle Service in air bag system section before performing service on or around the air bag syst

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